2016 (C - 16) DIPLOMA IN METALLURGICAL ENGINEERING ...

i

CURRICULUM - 2016(C - 16)

DIPLOMA INMETALLURGICAL ENGINEERING

STATE BOARD OFTECHNICAL EDUCATION & TRAINING

HYDERABADTELANGANA STATE

iii

CONTENTSS.NO CONTENT Page No.I PREAMBLE 1II RULES AND REGULATIONS 31. Admission Procedures 3

2. Scheme of Examination 6

3. Rules of Promotion to Next Level 9

4. Students Performance evaluation 15

5. Issue of Certificates and Veto 20

III SYLLABUS 21

I YEARI SEMESTER

S.No Subject Subject Page No.Code

1 MET-101 English-I 29

2 MET-102 Engineering Mathematics - I 34

3 MET-103 Engineering Physics-I 40

4 MET-104 Engineering chemistry & 45Environmental studies-I

5 MET-105 Mineral Processing Technology-I 50

6 MET-106 Elements of Metallurgical 53Engineering-I

PRACTICALS

7 MET-107 Engineering Drawing-I 56

8 MET-108 Basic Workshop Practice-I 64

9 MET-109 Physics Lab Practice -I 68

10 MET-110 Chemistry Lab Practice-I 71

11 MET-111 Computer Fundamentals 74Lab Practice-I

iv

II SEMESTER1 MET-201 English -II 82

2 MET-202 Engineering Mathematics - II 84

3 MET-203 Engineering Physics-II 92

4 MET-204 Engineering chemistry & 98Environmental studies-II

5 MET-205 Mineral Processing Technology-II 103

6 MET-206 Elements of Metallurgical 106Engineering-II

PRACTICALS

7 MET-207 Engineering Drawing-II 109

8 MET-208 Basic Workshop Practice-II 113

9 MET-209 Physics Lab Practice-II 116

10 MET-210 Chemistry Lab Practice-II 119

11 MET-211 Computer FundamentalsLab Practice-II 122

III SEMESTER1 MET-301 Engineering Mathematics -III 129

2 MET-302 Fuels, Refractories and Pyrometry 134

3 MET-303 Metallurgical Thermodynamics 139

4 MET-304 Physical Metallurgy 145

5 MET-305 Iron Making 152

PRACTICALS

6 MET-306 Machine Drawing 1577 MET-307 Fuels Lab Practice 1638 MET-308 Communication skills and 167

Life skills Lab Practice9 MET-309 Metallography lab Practice-I 17110 MET-310 Mineral dressing lab Practice 174

v

IV SEMESTER1 MET-401 Engineering Mathematics -IV 1822 MET-402 Electrical technology 1863 MET-403 Material Testing 1914 MET-404 Foundry Technology 1975 MET-405 Heat Treatment Technology 2066 MET-406 Steel Making 214

PRACTICALS

7 MET-407 Material Testing Lab Practice-I 2198 MET-408 Heat Treatment Lab Practice 2229 MET-409 Foundry Lab Practice 22710 MET-410 Programming in C Lab Practice 232

V SEMESTERIndustrial Training (I Spell) 238

VI SEMESTERIndustrial Training (II Spell) 238

VII SEMESTER1 MET-701 Industrial Management and

Entrepreneurship 241

2 MET-702(A) Welding Technology 249

MET-702(B) Corrosion Engineering 256

3 MET-703 Metal Casting Technology 261

4 MET-704 Mechanical Metallurgy 267

5 MET-705 Non Ferrous ExtractiveMetallurgy 273

PRACTICALS

6 MET-706 Material Testing Lab Practice-II 279

7 MET-707 Metal Casting Lab Practice 282

vi

8 MET-708 CAD Lab Practice 285

9 MET-709 Metallography Lab Practice-II 292

10 MET-710 Project work and Viva-Voce 294

1

CURRICULUM (C-16) Semester PatternFOR DIPLOMA COURSES IN TELANGANA

I. PREAMBLEThe State Board of Technical Education and Training,

Telangana under the aegis of the Department of Technical Education,Telangana generally reviews the Curricula to tune up the updateddevelopment both in academic and industry side. However,recognizing the changing needs as stated by the user industries, theBoard has decided to bring forward the revision of curriculum.Consequently the Board with the assistance of senior faculty of theconcerned branches has performed the evaluation of C-14Curriculum in force. On finding the merits and demerits of C-14Curriculum the faculty have made a thorough assessment of thecurricular changes that have to be brought in. It was felt that there isan urgent need to improve hands-on experience among the studentspursuing diploma courses. Further, the urgency of enhancingcommunication skills in English was also highlighted in the feedbackand suggestions made by the user industries. Keeping these in view,a number of meetings and deliberations were held at state level, withexperts from industry, academia and senior faculty of the department.The new Curricula for the different diploma courses have beendesigned with the active participation of the members of the facultyteaching in the Polytechnics of Telangana, besides reviewed by ExpertCommittee constituted with eminent academicians.

The primary objective of the curriculum change is to producebest technicians in the country by correlating growing needs of theindustries with the academic input.

The revised New Curriculum i.e., Curriculum – 2016 or C-16 isplanned and designed duly introducing semester pattern in 1st yearand 6 months industrial training in 3rd year level (5th or 6th semester)to have good exposure with industries and it will be implementedfrom the academic year 2016-17.Salient Features:1. Duration of course is 3 years / 3½ years of Regular Academic

Instruction.2. The entire Curriculum is prepared in Semester Pattern right

from 1st year.

2

3. Six months Industrial Training is placed in VI semester to acquirethe industrial exposure and experience for the students.

4. Mathematics, Physics and Chemistry is common to allbranches in 1st and 2nd semester except Foot Wear, DCCP,DCT, DHS, DHMCT & DGT branches.

5. Mathematics-III at 3rd semester level is common to all branchesexcept DCT, DHS, DCCP, DGT and DHMCT.

6. Programming in ‘C’ lab is introduced in 4th Semester inconsideration with the AICTE model curriculum and to meetNBA requirement.

7. The policy decisions taken at the State and Central level withregard to environmentalscienceare implemented by includingrelevant topics in Chemistry. This is also in accordance withthe Supreme Court guidelines issued in Sri Mehta’s case.

8. Keeping in view of the increased need of communication skillswhich is playing a vital role in the success of Diploma Levelstudents in the Industries, emphasis is given for learning andacquiring listening, speaking, reading and writing skills inEnglish. Further as discussed in the Curriculum meetings,Communication Skills and Life Skills lab is introduced in IIIsemester for all the branches.

9. Modern topics relevant to the needs of the industry and globalscenario suitable to be taught at Diploma level are alsoincorporated in the curriculum.

10. Introduction of CAD/CAM specific to the branch has been givenmore emphasis in the curriculum for preparing drawings usingCAD and also preparation of Part programme for CAM software.

11. Every student is exposed to the computer lab at the 1st and 2nd

semester level itself in order to familiarize himself/herself withthe operating systems.

12. The number of teaching hours allotted to a particular topic/chapter has been rationalized keeping in view the pastexperience

13. Upon reviewing the existing C-14 curriculum, more emphasisis given to the practical content of Laboratories and Workshops,thus strengthening the practical skills.

3

14. With increased emphasis for the student to acquire Practicalskills, the course content in all the subjects is thoroughlyreviewed and structured as outcome competency based thanthe conventional based. While the course content in certainsubjects felt overloaded is reduced, in rest of the subjects thecontent has been enhanced as per the need.

15. All Practical subjects are independent of each other and thepractice of grouping two or more practical subjects is dispensedwith.

16. Laboratory and Workshops practicals have been thoroughlyrevised based on the suggestions received from the industryand faculty, for better utilization of the equipment available atthe Polytechnics. The experiments /exercises that are chosenfor the practical sessions are identified to conform to the fieldrequirements of industry.

17. The Members of the working group are grateful to Smt. A. VaniPrasad, I.A.S., Commissioner of Technical Education&Chairperson, S.B.T.E.T. Telangana for her constant guidanceand valuable inputs in revising, modifying and updating thecurriculum.

18. The Members acknowledge thanks for cooperation andguidance extended by Sri. D. Venkateswarlu, Secretary andhis team of SBTET, Telangana and other officials of Directorateof Technical Education and the State Board of TechnicalEducation, Telangana, experts from industry, academia fromthe universities and higher learning institutions and all teachingfraternity from the Polytechnics who are directly or indirectlyinvolved in preparation of the curricula.

II. RULES AND REGULATIONS1. ADMISSION PROCEDURES:1.1 DURATION AND PATTERN OF THE COURSES

All the Diploma programs run at various institutions are of AICTEapproved 3 years or 3½ years duration of Academic Instruction.

All the Diploma courses are run in the semester pattern andincorporated 6 months Industrial Training as integral part of theCurriculum in 5th semester. In respect of few courses, the trainingwill be in the seventhsemester.

4

1.2 PROCEDURE FOR ADMISSION INTO THE DIPLOMACOURSES:

Selection of candidates is governed by the Rules and regulationslaid down in this regard from time to time.i) Candidates who wish to seek admission in any of the Diploma

courses will have to appear for Common Entrance Test foradmissions into Polytechnics (POLYCET) conducted by theState Board of Technical Education and Training, Telangana,Hyderabad.Only the candidates satisfying the following requirements willbe eligible to appear for the Common Entrance Test foradmissions into Polytechnics (POLYCET).

a) The candidates seeking admission should have appeared forthe X class examination, conducted by the Board of SecondaryExamination, Telangana or equivalent examination thereto, atthe time of making application to the Common Entrance Testfor Polytechnics for admissions into Polytechnics (POLYCET).In case of candidates who apply pending results of theirqualifying examinations, their selection shall be subject toproduction of proof of their passing the qualifying examinationin one attempt or compartmentally at the time of interview foradmission.

b) Admissions are made based on the merit obtained in theCommon Entrance Test (POLYCET) duly following thereservation rules stipulated by the Government of Telanganafrom time to time.

c) For admission into the following Diploma Courses for whichentry qualification is 10+2, candidates need not appear forPOLYCET. A separate notification will be issued for admissioninto these courses.1). D.H.M.C.T. 2). D.Pharmacy

1.3 MEDIUM OF INSTRUCTIONThe medium of instruction and examination shall be English.

1.4 PERMANENT IDENTIFICATION NUMBER (PIN)A cumulative / academic record shall be maintained in respect

of the Marks secured in sessional work and end examination of each

5

semester for determining the eligibility for promotion etc., a PermanentIdentification Number (PIN) will be allotted to each candidate so asto facilitate this work and avoid errors in tabulation of results.1.5 NUMBER OF WORKING DAYS PER SEMESTER:a). The Academic year for all the Courses usually shall be from

June 2nd week of the year of admission to the 31st March of thesucceeding year.

b). The Working days in a week shall be from Monday to Saturday.c). There shall be 7 periods of 50 minutes duration on all working

days.d). The minimum number of working days for each semester shall

be 90 days excluding end examination days. If this prescribedminimum is not achieved due to any reason, specialarrangements shall be made to conduct classes to make upthe working days and to cover the syllabus.

1.6 ELIGIBILITY OF ATTENDANCE TO APPEAR FOR THEEND EXAMINATION

a). A candidate shall be permitted to appear for the end examinationin all subjects, if he or she has attended a minimum of 75% ofworking days during the Semester.

b). Condonation of shortage of attendance in aggregate upto 10%(65% and above and below 75%) in each semester shall begranted on medical grounds subject to production of medicalcertificate from the Govt. Doctor not below the rank of Asst.Civil Surgeon.

c). Candidates having less than 65% attendance shall be detained.d). Students whose shortage of attendance is not condoned in

any semester are not eligible to take their end examination ofthat class and their admissions shall stand cancelled. Theymay seek re-admission for that semester when offered next.

e). A stipulated fee shall be payable towards condonation forshortage of attendance.

1.7 READMISSIONReadmission shall be granted to eligible candidates by the

respective Principal for the students who applies for readmissionwithin the year i.e., subsequent next academic year. Otherwise, it

6

has to be referred to the RJD. The readmissions shall be processed1) Within 15 days after commencement of class work in any

semester (Except industrialTraining).2) Within 30 days after commencement of class work for D.

Pharmacy course since it is year wise pattern.Otherwise such cases shall not be considered for readmission

for that semester/year and are advised to seek readmission in thenext subsequent eligible academic year by referring it to RJD.

The percentage of attendance of the readmitted candidatesshall be calculated from the first day of begining of the regular classwork for that year / Semester, as officially announced by CTE/SBTETbut not from the day on which he/she has actually reported to theclass work, after readmission is granted.

2. SCHEME OFEXAMINATION2.1 I. II, III, IV, V, VI and VII Semesters:

THEORY EXAMINATION: Each theory subject carries usually80 marks and 60 marks in respect of Drawing and Laboratories/Workshops of 3hours duration, along with 20/40 marks for internalevaluation (sessional marks) respectively.

PRACTICAL EXAMINATION: Each subject carry 60/30 marksof 3hours duration 40/20 sessional marks, however in specifiedsubjects it is 30:20 ratio.2.2 INTERNAL ASSESSMENT SCHEMEa) Theory Subjects: Theory Subjects carry 20 sessional marks,

Internal examinations will be conducted for awarding sessionalmarks on the dates specified. Two Unit Tests will beconducted in each semester. Average of marks obtained inall the prescribed tests will be considered for awarding the 10sessional marks. For remaining 10 sessional marks, 5 forassignment and 5 for group discussion & seminar.

b) Practicals: Student’s performance in Laboratories / Workshopshall be assessed during the year of study for 40 marks ineach practical subject. Allotment of internal marks of 20 shouldbe discrete taking into consideration of the students skills,accuracy, recording and 20 of internal marks for performanceof the task assigned to him / her lab practicals assessmenttest is on par with Unit test. Each student has to write a record

7

/ log book for assessment purpose. In the subject of Drawing,which is also considered as a practical paper, the same ruleshold good. Drawing exercises are to be filed in seriatum.

c) Internal assessment in Labs / workshops / Survey field etc.,during the course of study shall be done and sessional marksshall be awarded by the concerned Lecturer / Senior Lecturer/ Workshop superintendent with the concurrence of concernedHOS as the case may be.

d) For practical examinations, except in drawing, there shall betwo examiners. External examiner shall be appointed by thePrincipal in consultation with respective head of sectionpreferably choosing a person from an Industry. Internal examinershall be the person concerned with internal assessment as in(c) above. The end examination shall be held along with alltheory papers in respect of drawing.

e) Question Paper for Practicals: Question paper should coverall the experiments /exercise prescribed.

f) Records pertaining to internal assessment marks of both theoryand practical subjects are to be maintained for official inspectionand preserved.

g) Evaluation and assessment of industrial training, shall bedone and marks be awarded in the following manner.

Industrial assessment : 200 marks (in two spells of 100marks each)

Maintenance of log book : 30 marksRecord Work : 30 marksSeminar/viva-voce : 40 marks

_________TOTAL 300 marks

_________The assessment at the institute level will be done by a minimum

of three members Internal Faculty, Industrial Experts and H.O.D. andbe averaged for finalizing the marks.

2.3 MINIMUM PASS MARKSTHEORY EXAMINATION:

For passing a theory subject, a candidate has to secure a

8

minimum of 35% in end examination and a combined minimum of35% of both Sessional and end examination marks put together.PRACTICAL EXAMINATION:

For passing a practical subject, a candidate has to secure, aminimum of 50% in end examination and a combined minimum of50% of both sessional and end examination marks put together. Incase of D.C.C.P., the pass mark for typewriting and Shorthand is45% in the end examination. There are no sessional marks fortypewriting and Shorthand subjects of D.C.C.P course.

2.4 PROVISION FOR IMPROVEMENT1. Improvement is allowed only after he / she has completed all

the subjects from First semesterto Final semester of theDiploma.

2. Improvement is allowed in any 4(Four) subjects of the Diploma.3. The student can avail improvement chance only once, that too

within the succeeding two examinations after the completionof Diploma, with the condition that the duration includingImprovement examination shall not exceed FIVE years fromthe first admission.

4. No improvement is allowed in Practical / Lab subjects or Projectwork or Industrial Training assessment. However, improvementis allowed in drawing subject.

5. If improvement is not achieved, the marks obtained in previousExaminations hold good.

6. Improvement is not allowed in respect of the candidates whoare punished under Mal-practice in any Examination.

7. Examination fee for improvement shall be paid as per thenotification issued by State Board of Technical Education andTraining from time to time.

8. All the candidates who wish to appear for improvement ofperformance shall deposit the original Marks Memos of all theyears / Semesters and also original Diploma Certificate to theBoard. If there is improvement in performance of the currentexamination, the revised Memorandum of marks and OriginalDiploma Certificate will be issued or else the submittedoriginals will be returned.

9

2.5 PROVISION FOR INSTANT EXAMINATION:i. The candidate shall be on regular rolls of final during academic

year and last appeared for exams from the scheme inforcebasing on industrial training slot allotted.

ii. The candidate should not have more than two backlog subjects(either theory or practical or both) put together i.e., from 1styear to 5th/7th semester (in case of sandwich courses)However, (a) the candidate registered/appeared for instant

examination are not eligible to appear for winter session ofsupplementary examination. (b) The candidates awarded punishment under malpractice is noteligible.

PROMOTION RULES AND ELIGIBILITY CONDITIONSOF C-16 CURRICULUM

3 RULES OF PROMOTION TO NEXT LEVEL:3.1 For Diploma Courses (Except Metallurgy, Chemical Engg.,Textile Technology, Footwear Technology) of 1st, 2nd, 3rd, 4th,5th and 6th Semesters:1. A candidate shall be permitted to appear for first semester

examination provided he / she puts the required percentage ofattendance (i.e., 75%) and pays the examination fee. However,attendance can be condoned by the Principal on Medicalgrounds upto 10% ( i.e. attendance after condonation on Medicalgrounds should not be less than 65%) and he/she has to paythe condonation fee along with examination fee as prescribedby SBTET from time to time.

2. A candidate shall be promoted to 2nd semester if he/she putsthe requisite percentage of attendance (i.e., 75% in generaland 65% on medical grounds) in the 1st semester and paysthe examination fee. A candidate who could not pay the 1st

semester examination fee has to pay the promotion fee asprescribed by SBTET from time to time before commencementof 2nd semester.

3. A candidate shall be promoted to 3rd semester if he/she putsthe requisite percentage of attendance (i.e., 75% in generaland 65% on medical grounds) in the 2nd semester and pays

10

the examination fee. A candidate who could not pay the 2nd

semester examination fee has to pay the promotion fee asprescribed by SBTET from time to time before commencementof 3rd semester.A candidate is eligible to appear for the 3rd semester exam if

he/she puts the requisite percentage of attendance (i.e., 75% ingeneral and 65% on medical condonation) in the 3rd semester.4. A candidate shall be promoted to 4th semester provided he/

she puts the requisite percentage of attendance (i.e., 75% ingeneral and 65% on medical condonation) in the 3rd semesterand pays the examination fee of 3rd semester. A candidate whocould not pay the 3rd semester exam fee, has to pay thepromotion fee as prescribed by State Board of TechnicalEducation and Training from time to time beforecommencement of 4th semester.A candidate is eligible to appear for the 4th semester exam if

he/shea) Should have requisite % of attendance i.e., 75%, on

condonation due to Medical grounds 65% to appear for 4th

semester.b) Should not have failed in more than 6 backlog subjects of 1st

and 2nd semester put together.5. A candidate shall be promoted to 5th semester( T h e o r y /

Industrial Training) as the case may be provided he /she putsthe required percentage of attendance (i.e., 75% in general and65% on medical grounds) in the 4th semester and pays theexamination fee. A candidate, who could not pay the 4th semesterexamination fee, has to pay the promotion fee as prescribedby State Board of Technical Education and Training from timeto time before commencement of 5th semester as the casemay be in respect of the following.A candidate is eligible to appear for 5th semester exam, if he/

shei. THEORY:a. Should have requisite % of attendance i.e., 75%, on condonation

due to Medical grounds 65% to appear for 5th semester.b. Should have appeared for 4th semester examination.

11

c. IVC students should not have failed in more than 2 backlogsubjects of 3rd semester

ii. INDUSTRIAL TRAINING (In Case Swapped):a. Should have requisite % of attendance i.e., 90% in V semester.b. Should have appeared for 4th semester examination.6. A candidate shall be promoted to 6th semester (Theory/Industrial

Training) as the case may be provided he /she puts the requiredpercentage of attendance (i.e., 75% in general and 65% onmedical grounds, 90% in case of Industrial Training) in the 5th

semester and pays the examination fee. A candidate, who couldnot pay the 5 th semester examination fee, has to pay thepromotion fee as prescribed by State Board of TechnicalEducation and Training from time to time beforecommencement of 6th semester as the case may be in respectof the following.A candidate is eligible to appear for 6th semester exam, if he/

shei. THEORY (In Case Swapped):a. Should have requisite % of attendance i.e., 75%, on condonation

due to Medical grounds 65% to appear for 6th semester.b. Should have appeared for 4th semester examination.c. Should have completed Industrial Training in V semester (in

case swapped)d. IVC students should not have failed in more than 2 backlog

subjects of 3rd semesterii. INDUSTRIAL TRAINING:a. Should have requisite % of attendance i.e., 90% in VI semester.b. Should have appeared for 4th semester examination.

3.2 For Diploma Courses of 3 ½ Years duration3.2.1 (Metallurgy/ Chemical Engg./ Textile Technology)1. A candidate shall be permitted to appear for first semester

examination provided he / she puts the required percentage ofattendance (i.e., 75%) and pays the examination fee. However,attendance can be condoned by the Principal on Medicalgrounds upto 10% (i.e. attendance after condonation on Medical

12

grounds should not be less than 65%) and he/she has to paythe condonation fee along with examination fee as prescribedby SBTET from time to time.

2. A candidate shall be promoted to 2nd semester if he/she putsthe required percentage of attendance in the 1st semester andpays the examination fee. A candidate who could not pay the1st semester examination fee has to pay the promotion fee asprescribed by State Board of Technical Education and Trainingfrom time to time before commencement of 2nd semester. Acandidate is eligible to appear for the 2nd semester exam, if he/she put the required percentage of attendance in 2nd semester.

3. A candidate shall be promoted to 3rd semester if he/she putsthe required percentage of attendance in the 2nd semester andpays the examination fee. A candidate who could not pay the2nd semester examination fee has to pay the promotion fee asprescribed by State Board of Technical Education and Trainingfrom time to time before commencement of 3rd semester. Acandidate is eligible to appear for the 3rd semester exam, if he/she put the required percentage of attendance in 3rd semester.

4. A candidate shall be promoted to 4th semester provided he/she puts the required percentage of attendance in the 3 rd

semester and pay the examination fee. A candidate, who couldnot pay the 3rd semester exam fee, has to pay the promotionfee as prescribed by State Board of Technical Education andTraining from time to time before commencement of 4th

semester.A candidate is eligible to appear for the 4th semester exam ifhe/she

a. Should have requisite % of attendance i.e., 75%, on condonationdue to Medical grounds 65% to appear for 4th semester.

b. Should not have failed in more than 6 backlog subjects of 1st

and 2nd semester put together5. A candidate shall be promoted to 5th semester provided he /

she puts the required percentage of attendance in the 4 th

semester and pays the examination fee. A candidate, who couldnot pay the 4 th semester examination fee, has to pay thepromotion fee as prescribed by State Board of TechnicalEducation and Training from time to time before

13

commencement of 5th semester.6. Promotion from 5th to 6th semester is automatic (i.e., from 1st

spell of Industrial Training to 2nd spell) provided he/she puts therequired percentage of attendance, which in this case wouldbe 90 % attendance and attends for the VIVA-VOCEexamination at the end of training.

Industrial Training:A candidate is eligible to go for Industrial Training if he/sheShould have requisite % of attendance i.e., 90% in V & VIsemester.

7. A candidate shall be promoted to 7th semester of the courseprovided he/she has successfully completed both the spells ofIndustrial Training.A candidate is eligible to appear for 7th semester examination ifhe/she

Theory:a. Should have requisite % of attendance i.e., 75%, on condonation

due to Medical grounds 65% to appear in 7th semester.b. Should have appeared 4th semester Examinationc. Should have completed Industrial Trainingd. IVC students should not have failed in more than 2 backlog

subjects of 3rd semester.

3.2.2 For Diploma Courses of 3½ Years duration: FWIn respect of Diploma in Footwear Technology, the Industrial

training is offered in two spells, the 1st spell of Industrial training afterthe 2nd semester (i.e. III semester of the course) and the secondspell of industrial training after the VI semester (i.e VII Semester ofthe course). The promotion rules for this course are on par with theother sandwich Diploma courses except that there is no restrictionon number of backlog subjects to get eligibility to appear for the 4thsemester examination

A candidate is eligibility to appear for 4th semester exam, if he/shea. Should have requisite % of attendance i.e., 75%, on condonation

due to Medical grounds 65% to appear for 4th semester.

14

b. Should have completed Industrial Training and appeared forViva-Voce in III semester

i. A candidate is eligible to appear for 5th semester examinationif he/she

a. Should have requisite % of attendance i.e., 75%, on condonationdue to Medical grounds 65% to appear for 5th semester.

b. Should not have failed altogether in more than 6 backlogsubjects of 1st and 2nd semesters.A candidate shall be promoted to 6th semester provided he /

she puts the required percentage of attendance in the 5th semesterand pays the examination fee, a candidate, who could not pay the 5th

semester examination fee, has to pay the promotion fee as prescribedby State Board of Technical Education and Training from time to timebefore commencement of 6th semester.ii. A candidate is eligible to appear for 6th semester examination

if he/she,Theory:a. Should have requisite % of attendance i.e., 75%, on condonation

due to Medical grounds 65% to appear in 6th semester.b. Should have appeared 5th semester Examination.3.3 OTHER DETAILSa) In case acandidate does not successfully complete the

Industrial training, he / she will have to repeat the training at his/ her own cost.

b) The 1stspell of Industrial training shall commence 10 days afterthe completion of the last theory examination of IV semester.

c) The 2nd spell of Industrial training shall commence within 10days after the completion of 5th semester besides successfulcompletion of 1st spell of Industrial training.

d) Each Semester of Institutional study shall be a minimum of 90working days. (With 6 working days in a week i.e. from Mondayto Saturday, with 7 periods of 50 minutes duration per day).

4 STUDENTS PERFORMANCE EVALUATION4.1 AWARD OF DIPLOMA

Successful candidates shall be awarded the Diploma under

15

the following divisions of pass.1. First Class with Distinction shall be awarded to the candidates

who secure an overall aggregate of 75% marks and above.2. First Class shall be awarded to candidates who secure overall

aggregate of 60% marks and above and below 75% marks.3. Second Class shall be awarded to candidates who secure a

pass with an overall aggregate of below 60%.The Weightage of marks for various year/Semesters which

are taken for computing overall aggregate shall be 25% of 1st and 2nd

semester marks + 100% of 3rd and subsequent Semesters.With respect to the intermediate vocational candidates who

are admitted directly into diploma course at the 3rd semester (i.e.,second year) level the aggregate of (100%) marks secured at the 3rd

and subsequent semesters of study shall alone be taken intoconsideration for determining the overall percentage of marks securedby the candidates for award of class/division.4. Second Class Diploma course certificate shall be awarded to

all students, who fail to complete the Diploma with in stipulatedtime i.e., double the duration of the course and subsequentlypass in mercy/special mercy chances.

4.2 EXAMINATION FEE SCHEDULE:The examination fee should be paid as per the notification issued

by State Board of Technical Education and Training from time to time.4.3 STRUCTURE OF END EXAMINATION QUESTION

PAPER:The question paper for theory examination is patterned in such

a manner that the Weightage of periods/marks allotted for each ofthe topics for a particular subject be considered.

Examination paper is of 3/6/9 hour’s duration for general andArchitectural Assistantship respectively.a) In case of 1st and 2nd semesters each theory paper consists of

Section ‘A’ and Section ‘B’. Section ‘A’ contains 20 short answerquestions out of which 15 questions are to be answered andeach question carries 2 marks Max. Marks: 15 x 2 = 30.

Section B contains 8 essay type questions including Numericalquestions, out of which 5 questions are to be answered each carrying

16

10 marks are to be answered.Max. Marks: 5 x 10 = 50. Total Maximum Marks: 80.

b) For Engineering Drawing Subjects (107 and 207) consist ofsection ‘A’ and section ‘B’. Section ‘A’ contains four (4) questions.All questions in section ‘A’ are to be answered and each questioncarries 5 marks. Max. Marks: 4 x 5=20. Section ‘B’ containssix (6) questions. Out of which four (4) questions are to beanswered and each question carries 10 Marks. Max. Marks 4 x10 =40.

c) Practical Examinations- For Workshop practice andLaboratory Examinations,Each student has to pick up a question from the designedquestion paper by Lottery System.Max. Marks for an experiment/exercise : 50Max. Marks for VIVA-VOCE : 10Total : 60In case of practical examinations with 50 marks, the marks willbe worked out basing on the above ratio.In case of the subsequent 3rd, 4th, 5th, 6th and 7th semestersexcluding Industrial Training semester each theory paperconsists of section ‘A’ and Section ‘B’. Section ‘A’ contains 10short answer questions in which all the 10 questions need tobe answered and each question carries 3 marks.Max. Marks 10 x 3 = 30Section B contains 8 essay type questions including Numericalquestions, out of which 5 questions are to be answered eachcarrying 10 marks are to be answered.Max. Marks: 5 x 10 = 50. Total Maximum Marks: 80.In case of any change in the pattern of question paper, thesame shall be informed sufficiently in advance to thecandidates.

4.4 ISSUE OF MEMORONDUM OF MARKSAll candidates who appear for the end examination will be issued

memorandum of marks without any payment of fee. Howevercandidates who lose the original memorandum of marks have to paythe prescribed fee to the Secretary, State Board of Technical Education

17

and Training, Telangana. for each duplicate memo.4.5 MAXIMUM PERIOD FOR COMPLETION OF DIPLOMA

COURSES:Maximum period for completion of the course is twice the

prescribed duration of the course from the date of First admission(includes the period of detention and discontinuation of studies bystudent etc) failing which they will have to for feit the claim for qualifyingfor the award of Diploma (They will not be permitted to appear forexaminations after that date). This rule applies for all Diploma coursesof 3 years and 3 ½ years of engineering and non-engineering coursesincluding candidates who seek admission under lateral entry. Inrespect of Pharmacy courses the completion period is 4 years asthe prescribed duration of the course is 2 years.

4.6 ELIGIBILITY FOR AWARD OF DIPLOMAA candidate is eligible for award of Diploma Certificate if he /

she fulfill the following academic regulations.i. He / She pursued a course of study for not less than 3 / 3 ½

academic years & not more than 6 / 7 academic yearsrespectively.

ii. He / she must have passed all the subjects.Students who fail to fulfill all the academic requirements for the

award of the Diploma within 6/7 academic years as the case may befrom the year of admission shall forfeit their seat in the course &their seat shall stand cancelled.4.7 RECOUNTING, ISSUE OF PHOTOCOPY OF VALUED

ANSWER SCRIPT & REVERIFICATION:4.7.1 a) A candidate desirous of applying for Recounting/ issueof

Photocopy of valued answer scripts/ Reverification shouldsubmit the application to the Secretary, State Board of TechnicalEducation and Training, Telangana., Hyderabad – 500 063 within15 days from thedate of receipt of Tabulated Marks Statementby the Principal of concerned Polytechnic or the date specifiedin the notification issued for Reverfication/Recounting.Recounting shall be done for any TWO theory subjects per

Semester only, including drawing subjects. No request for recountingshall be entertained from any candidate who is reported to haveresorted to Mal practice in that examination. The fee prescribed for

18

Recounting should be paid by way of Demand Draft drawn on anyScheduled Bank payable at Hyderabad in favour of the Secretary,State Board of Technical Education and Training, Telangana.,Hyderabad. The verification of the totaling will be done by an Officerof the Board and will be intimated to the candidate by postonly.

The following documents should be invariably be enclosed withthe application failing which the application will not be considered.4.7.1.1 Marks secured as per Tabulated Marks Sheet certified by

the Principal.4.7.1.2 The payment of prescribed fee shall be online as notified in

the circular issued from time to time.4.7.1.3 Self – addressed and stamped envelopes of 11" X 5" size.

The applications received after the prescribed date will not beaccepted and any correspondence in this regard will not beentertained.4.7.2 FOR ISSUE OF PHOTO COPIES OF VALUED ANSWER

SCRIPTS1. A candidate desirous of applying for Photo copy of valued

answer script/scripts should submit the application to theSecretary, State Board of Technical Education and Training,Telangana., Hyderabad – 500 063 along with the required feein the form of Demand Draft within 07 days from the date ofreceipt of Tabulated Marks Statement by the Principal ofconcerned Polytechnic or the date specified in the coveringletter whichever is earlier.

2. Photo copies of valued answer scripts will be issued to alltheory subjects including drawing subjects.

3. The following documents should invariably be enclosed withthe application

i. Marks secured as per Tabulated Marks Sheets certified by thePrincipal

ii. Self-addressed Stamped Envelope/Cloth-line cover of size 10’’x 14’’.

iii. Fee in the form as notified from time to time.

19

4.7.3 FOR RE-VERIFICATION OF THE VALUED ANSWERSCRIPT

1. A candidate desirous of applying for Re-verification of valuedanswer script should submit the application to the Secretary,State Board of Technical Education and Training, Telangana.,Hyderabad – 500 063 along with the required fee in the form ofDemand Draft, within 15 days from declaration of result.

2. Re-verification of valued answers cript shall be done for all theorysubjects including drawing subjects.

3. The following documents should invariably be enclosed withthe application failing which the application will not beconsidered.

(i) Marks secured as per Tabulated Marks Sheets certified by thePrincipal.

(ii) Fee in the form of Demand Draft.4.7.4 MALPRACTICE CASES:

If any candidate resorts to any Mal Practice duringexaminations, he / she shall be booked and the Punishment shall beawarded as per rules and regulations framed by SBTET from time totime.4.7.5 DISCREPANCIES/PLEAS:

Any Discrepancy /Pleas regarding results etc., shall berepresented to the Board within one month from the date of issue ofresults. Thereafter, no such cases shall be entertained in any manner.

5 ISSUE OF CERTIFICATES AND VETO5.1. ISSUE OF DUPLICATE DIPLOMA

If a candidate loses his/her original Diploma Certificate anddesires a duplicate to be issued he/she should produce writtenevidence to this effect. He / she may obtain a duplicate from theSecretary, State Boardof Technical Education and Training, Telanganaon payment of prescribed fee and on production of an affidavit signedbefore a First Class Magistrate (Judicial) and non-traceable certificatefrom the Department of Police. In case of damage of original DiplomaCertificate, he / she may obtain a duplicate certificate by surrenderingthe original damaged certificate on payment of prescribed fee to theState Board of Technical Education and Training.

20

In case the candidate cannot collect the original Diploma within1 year from the date of issue of the certificate, the candidate has topay the penalty prescribed by the SBTET from time to time.5.2 ISSUE OF MIGRATION CERTIFICATE AND

TRANSCRIPTS:The Board on payment of prescribed fee will issue these

certificates for the candidates who intend to pursue Higher Studiesin India or Abroad.

5.3 GENERALi. The Board may change or amend the academic rules and

regulations or syllabi at any time and the changes oramendments made shall be applicable to all the students, forwhom it is intended, with effect from the dates notified by thecompetent authority.

ii. All legal matters pertaining to the State Board of TechnicalEducation and Training are within the jurisdiction of Hyderabad.In case of any ambiguity in the interpretation of the above rules,

the decision of the Secretary, SBTET is final.*****

21

DIPLOMA IN METALLURGICAL ENGINEERING

SCHEME OF INSTRUCTIONS AND EXAMINATION

I SEMESTER

Subject Name of the No. of Total Scheme of Total Code Subject Periods Periods/ Examination Marks

/Week Semester

Theory Practi- Dura Sessi Endcal tion onal Exam

Hours Marks Marks

THEORY

MET-101 English-I 3 - 45 3 20 80 100

MET-102 EngineeringMathematics-I 5 - 75 3 20 80 100

MET-103 EngineeringPhysics-I 4 - 60 3 20 80 100

MET-104 Engineering Chemistry &EnvironmentalStudies-I 4 - 60 3 20 80 100

MET-105 Mineral ProcessingTechnology-I 4 - 60 3 20 80 100

MET-106 Elements ofMetallurgicalEngineering-I 4 - 60 3 20 80 100

PRACTICALS

MET-107 EngineeringDrawing-I - 6 90 3 40 60 100

MET-108 Basic WorkshopPractice-I - 6 90 3 40 60 100

MET-109 Physics LabPractice-I - 3 45 3 20 30 50

MET-110 Chemistry LabPractice-I - 3 20 30 50

MET-111 ComputerFundamentalsLab Practice-I - 3 45 3 40 60 100

TOTAL 24 18 630 -- 280 720 1000

22


SCHEME OF INSTRUCTIONS AND EXAMINATIONII SEMESTER


/Week Semester


Hours Marks Marks

THEORY

MET-201 English- II 3 - 45 3 20 80 100

MET-202 EngineeringMathematics-II 5 - 75 3 20 80 100

MET-203 EngineeringPhysics-II 4 - 60 3 20 80 100

MET-204 EngineeringChemistry andEnvironmentalStudies-II 4 - 60 3 20 80 100

MET-205 Mineral ProcessingTechnology-II 4 - 60 3 20 80 100

MET-206 Elements of MetallurglcalEngineering -II 4 - 60 3 20 80 100

PRACTICALS

MET-207 EngineeringDrawing-II - 6 90 3 40 60 100

MET-208 Basic Work ShopPractice-II - 6 90 3 40 60 100

MET-209 Physics LabPractice-II - 3 45 3 20 30 50

MET-210 Chemistry LabPractice-II 20 30 50

MET-211 ComputerFundamentalsLab Practice-II - 3 45 3 40 60 100

TOTAL 24 18 630 -- 280 720 1000

23

DIPLOMA IN METALLURGICAL ENGINEERINGSCHEME OF INSTRUCTIONS AND EXAMINATION

III SEMESTER


/Week Semester


Hours Marks Marks

THEORY

MET-301 EngineeringMathematics-III 4 - 60 3 20 80 100

MET-302 Fuels Refractoriesand Pyrometry 5 - 75 3 20 80 100

MET-303 MetallurgicalThermodynamics 4 - 60 3 20 80 100

MET-304 Physical Metallurgy 5 - 75 3 20 80 100

MET-305 Iron Making 5 - 75 3 20 80 100

PRACTICALS

MET-306 Machine Drawing - 6 90 3 40 60 100

MET-307 Fuels Lab practice - 3 45 3 40 60 100

MET-308 Communicationskills and Life skillsLab Practice - 4 60 3 40 60 100

MET-309 MetallographyLab Practice-I - 3 45 3 40 60 100

MET-310 Mineral DressingLab practice - 3 45 3 40 60 100

TOTAL 23 19 630 300 700 1000

24


IV SEMESTER


/Week Semester


Hours Marks Marks

THEORY

MET-401 EngineeringMathematics-IV 4 - 60 3 20 80 100

MET-402 ElectricalTechnology 4 - 60 3 20 80 100

MET-403 Material Testing 4 - 60 3 20 80 100

MET-404 Foundry Technology 5 - 75 3 20 80 100

MET-405 Heat TreatmentTechnology 5 - 75 3 20 80 100

MET-406 Steel Making 4 - 60 3 20 80 100

PRACTICALS

MET-407 Material TestingLab Practice-I - 3 45 3 40 60 100

MET-408 Heat TreatmentLab Practice - 6 90 3 40 60 100

MET-409 Foundry LabPractice - 3 45 3 40 60 100

MET-410 Programming inC Lab Practice - 4 60 3 40 60 100

TOTAL 26 16 630 280 720 1100

25

V SEMESTERIndustrial Training (I Spell)

VI SEMESTERIndustrial Training (II Spell)

26


VII SEMESTER


/Week Semester


Hours Marks Marks

THEORY

MET-701 Industrial Manage-ment andEntrepreneurship 4 - 60 3 20 80 100

MET-702A WeldingTechnology 5 - 75 3 20 80 100

MET-702B CorrosionEngineering

MET-703 Metal CastingTechnology 5 - 75 3 20 80 100

MET-704 MechanicalMetallurgy 5 - 75 3 20 80 100

MET-705 Non-ferrousExtractiveMetallurgy 5 - 75 3 20 80 100

PRACTICALS

MET-706 Material TestingLab Practice-II - 3 45 3 40 60 100

MET-707 Metal CastingLab Practice - 3 45 3 40 30 100

MET- 708 CAD Lab Practice 3 45 3 40 30 100

MET-709 MetallographyLab Practice -II 6 90 3 40 60 100

MET-710 Project work &Viva-voce - 3 45 3 40 60 100

TOTAL 24 18 630 300 640 1000

27

I SEMESTER

28


SCHEME OF INSTRUCTIONS AND EXAMINATION

I SEMESTER


/Week Semester


Hours Marks Marks

THEORY

MET-101 English-I 3 - 45 3 20 80 100

MET-102 EngineeringMathematics-I 5 - 75 3 20 80 100

MET-103 EngineeringPhysics-I 4 - 60 3 20 80 100

MET-104 Engineering Chemistry &EnvironmentalStudies-I 4 - 60 3 20 80 100

MET-105 Mineral ProcessingTechnology-I 4 - 60 3 20 80 100

MET-106 Elements ofMetallurgicalEngineering-I 4 - 60 3 20 80 100

PRACTICALS

MET-107 EngineeringDrawing-I - 6 90 3 40 60 100

MET-108 Basic WorkshopPractice-I - 6 90 3 40 60 100

MET-109 Physics LabPractice-I - 3 45 3 20 30 50

MET-110 Chemistry LabPractice-I - 3 20 30 50

MET-111 ComputerFundamentalsLab Practice-I - 3 45 3 40 60 100

TOTAL 24 18 630 -- 280 720 1000

29

ENGLISH -I(Common to All the Branches)

First SemesterSubject Title : English - ISubject Code : MET-101No. of periods per week : 03No. of periods per Semester : 45

TIME SCHEDULES. Major Topics No. of Weightage Short Essay

No Periods of Marks Type TypeQuestions Questions

1. Speaking 9 26 8 1

2. Grammar 22 34 12 1 (Quest-ioning)

3. Reading 6 20 - 2

4. Writing 8 40 - 4 (2 fromparagraph

writing,2 fromletter

writing)

Total 45 120 20 8

30

OBJECTIVES AND KEY COMPETENCIESS.No. Name of Unit

01 Need forEnglish

02 ClassroomEnglish

03 ExpressingFeelings

04 ExpressingLikes andDislikes

05 Making requests

06 The MightyMountain andLittle Lads ofTelangana

07 Adventures ofToto

Objectives

Understand the needto learn EnglishFind solutions tosome problems ofLearning English

Identify expressionsuseful in theclassroomUse classroome x p r e s s i o n smeaningfully

Express feelingsSpeak about whatothers feel

Express likes anddislikesExpress likes anddislikes of others

Learn some ways ofmaking requestsLearn some ways ofoffering help

Comprehend thecentral ideaLearn aboutExpeditions

Read and compre-hend the main ideaAppreciate a humo-rous narrative

Key Competencies

Know the need to learnEnglishIdentify the problemsstudents face in learning|EnglishDiscuss the varioussolutions to overcomethem

How to greet the teacherand other studentsLearn the expressionsfrequently used by theteacherPractise to expressone's ideas in English

Know the structures toexpress feelingsUse the vocabularyrelated to feelings

Study the different waysto express likes anddislikesLearn several words andphrases to express likesand dislikes

Examine the variousstructures to makerequestsLearn to make requestsin formal and informalsituations

Understand the mainideaPractise to read aloudLearn new vocabulary

Understand the centralideaLearn to make infere-nces

31

Read and understandthe main ideaImprove vocabulary

Differentiate betweentime and tenseDescribe habits andfacts

Describe the actionshappening in thepresentDescribe past actionsas relevant to thepresent

Understand whatirregular verbs areDescribe actions whichtook place in the past

Describe an action thatwas happening in thepastDescribe a past actionthat took place beforeanother past action

Describe future actionsUnderstand variousaspects of future tense

Understand basicsentence structures

Learn new vocabularyComplete a story

Focus on minute detailsDevelop innovative skillsPresent one's view

Learn the three broadcategories of tenseLearn the action wordsand auxiliary wordsLearn the simplepresent tense structureTalk about routine, habitsand factsMake negativesentences

Express the actionshappening in the presentExpress the actions thathave been completed inthe recent pastMake sentences in thepresent perfectcontinuous tense

Learn the irregular verbsNarrate the stories orincidents in simple pasttense

Describe the actions inprogress in the pastUse past perfect tense

Express the actions thatare going to happen inthe futureKnow the uses of themodals

Learn how English isdifferent from IndianLanguages from

08 Tiller TurnsEngineer - AnInnovation

09 The PresentTense- I

10 The PresentTense- II

11 The Past Tense- I

12 The Past Tense-II

13 The Future Tense

14 Basic SentenceStructures- I

32

Use basic sentencestructures in spokenand in written formsIdentify common errorsin the usage of basicsentence structures

Understand basicsentence structuresForm basic sentencestructures

Identify and use thepassive voiceKnow when the passivevoice is usedUse the passive voice

Identify the two objectsof a verbOmit the object in apassive voice sentence

Understand the wordorder in questionsAsk yes/no questions

Frame wh- questionsSeek information usingsuch questions

Generate ideas forwriting a paragraphOrganize ideas beforewriting

structures point of viewLearn intransitive verbsUse Subject +VerbstructureUse Subject + Verb +Subject Complementstructure

Learn transitive verbswhich are followed byonly one objectLearn transitive verbswhich are followed bytwo objectsIdentify the structuresUse ObjectComplement structure

Learn when to use theactive voice and passivevoiceObserve the languageused in sign boards andnewspaper headlinesChange the voice

Change the voice whentwo objects are given

Communicate usingyes/no questionsInvert the position ofhelping verb to makequestionsKnow the commonerrors in framingquestions

Learn wh-wordsAsk for specif icinformation using wh-questions

Write a paragraph usinghintsOrganize the ideasWrite the rough draft

15 Basic SentenceStructures- II

16 Voice - I

17 Voice - II

18 Asking Yes/NoQuestions

19 Asking Wh-Questions

20 ParagraphWriting - I

33

Write a short paragraph

Identify a topic sentenceWrite a cohesiveparagraphWrite supportingsentences

Understand the formatof a personal letterWrite a personal letter

Understand the formatof an official letterWrite an official letter

Edit the paragraph tomake final copy

Write a short paragraphusing the first sentenceLearn a few ways ofbeginning paragraphWrite a few supportingsentencesWrite a short paragraph

Learn the maincomponents (the format)of a personal letterPractise a few ways ofgreetings, openings andclosuresWrite a personal letter

Know the format of officiallettersLearn the expressionsoften used in officiallettersWrite an official letterusing the hints

21 ParagraphWriting - II

22 Letter Writing - I

23 Letter Writing - II

34

ENGINEERING MATHEMATICS - I(Common to all branches)

Subject title : Engineering Mathematics-ISubject code : MET-102Periods per week : 05Total Periods per Semester : 75

Time Schedule with BLUEPRINT

S. Major Topic No of Periods Weightage Short Type Essay Type No of Marks

Unit - I Algebra Theory Practice R U App R U App

1 Logarithms 2 1 2 0 1 0 0 0 0

2 Partial Fractions 5 1 9 1 1 0 ½ 0 0

3 Matrices andDeterminants 18 6 25 2 3 0 0 ½ 1

Unit -IITrigonometry

4 Compound Angles 4 2 14 1 1 0 1 0 0

5 Multiple and Submultiple angles 6 3 16 1 2 0 0 1 0

6 Transformations 6 3 17 1 0 0 0 ½ 1

7 Inverse TrigonometricFunctions 6 2 17 1 0 0 ½ 1 0

8 Properties of triangles 2 0 4 2 0 0 0 0 0

9 Hyperbolic Functions 2 0 2 1 0 0 0 0 0

10 Complex Numbers 4 2 14 1 1 0 1 0 0

Total 55 20 120 11 9 0 3 3 2

Marks 22 18 0 30 30 20

R: Remembering type : 52 marks

U: Understanding type : 48 marks

App: Application type : 20 marks

35

ENGINEERING MATHEMATICS - ICOMMON TO ALL BRANCHES

ObjectivesUpon completion of the course the student shall be able to:

UNIT - IAlgebra1.0 Use Logarithms in engineering calculations1.1 Define logarithm and list its properties.

1.2 Distinguish natural logarithms and common logarithms.

1.3 Explain the meaning of e and exponential function.

1.4 State logarithm as a function and its graphical representation.

1.5 Use the logarithms in engineering calculations.

2.0 Resolve Rational Fraction into sum of Partial Fractions inengineering problems

2.1 Define the following fractions of polynomials:1. Rational,

2. Proper

3. Improper

2.2 Explain the procedure of resolving rational fractions of the typementioned below into partial fractions

i) ( )

( )( )( )f x

x a x b x c ii) 2

( )( ) ( )( )

f xx a x b x c

iii) 2( )

( )( )f x

x a x b iv) 2 2

( )( )( )

f xx a x b

3.0 Use Matrices for solving engineering problems3.1 Define a matrix and order of a matrix.

3.2 State various types of matrices with examples (emphasis on3rd order square matrices).

36

3.3 Compute sum, scalar multiplication and product of matrices.

3.4 Illustrate the properties of these operations such as associative,distributive, commutative properties with examples and counterexamples.

3.5 Define the transpose of a matrix and write its properties.

3.6 Define symmetric and skew-symmetric matrices.

3.7 Resolve a square matrix into a sum of symmetric and skew-symmetric matrices with examples in all cases.

3.8 Define minor, co-factor of an element of a 3 x 3 square matrixwith examples.

3.9 Expand the determinant of a 3 x 3 matrix using Laplaceexpansion formula.

3.10 Distinguish singular and non-singular matrices.

3.11 Apply the properties of determinants to solve problems.

3.12 Solve system of 3 linear equations in 3 unknowns usingCramer's rule.

3.13 Define multiplicative inverse of a matrix and list properties ofadjoint and inverse.

3.14 Compute adjoint and multiplicative inverse of a square matrix.

3.15 Solve system of 3 linear equations in 3 unknowns by matrixinversion method

3.16 State elementary row operations.

3.17 Solve a system of 3 linear equations in 3 unknowns by Gauss-Jordan method

UNIT - IITrigonometry:4.0 Solve simple problems on Compound Angles4.1 Define compound angles and state the formulae of Sin (A±B),

Cos (A±B), tan (A±B) and Cot (A±B)

4.2 Give simple examples on compound angles to derive the valuesof Sin150, Cos150, Sin750, Cos750, tan 150, tan750 etc.

37

4.3 Derive identities like Sin (A+B) .Sn (A-B) = Sin 2 A - Sin2 B etc.

4.4 Solve simple problems on compound angles.

5.0 Solve problems using the formulae for Multiple and Sub-multiple Angles

5.1 Derive the formulae of multiple angles 2A, 3A etc. and submultiple angles A/2 in terms of angle A of trigonometric functions.

5.2 Derive useful allied formulas like sin2A = (1- cos2A)/2 etc.

5.3 Solve simple problems using the above formulae

6.0 Apply Transformations for solving the problems inTrigonometry

6.1 Derive the formulae on transforming sum or difference of twotrigonometric ratios in to a product and vice versa - exampleson these formulae.

6.2 Solve problems by applying these formulae to sum or differenceor product of three or more terms.

7.0 Use Inverse Trigonometric Functions for solvingengineering problems

7.1 Explain the concept of the inverse of a trigonometric functionby selecting an appropriate domain and range.

7.2 Define inverses of six trigonometric functions along with theirdomains and ranges.

7.3 Derive relations between inverse trigonometric functions sothat given A=sin-1x, express angle A in terms of other inversetrigonometric functions - with examples.

7.4 State various properties of inverse trigonometric functions and

identities like sin-1x + cos-1 x = 2

etc.

7.5 Derive formulae like

1 1 1tan tan tan

1

x yx y

xy

, 0, 0, 1where x y xy etc., and solve

simple problems.

38

8.0 Appreciate Properties of triangles

8.1 State sine rule, cosine rule, tangent rule and projection rule.

9.0 Represent the Hyperbolic Functions in terms of logarithmfunctions

9.1 Define Sinhx, Coshx and Tanhx and list the hyperbolic identities.

9.2 Represent inverse hyperbolic functions in terms of logarithms.

10.0 Represent Complex numbers in various forms10.1 Define complex number, its modulus and conjugate and list

their properties.

10.2 Define the operations on complex numbers with examples.

10.3 Define amplitude of a complex number

10.4 Represent the complex number in various forms like modulus-amplitude (polar) form, Exponential (Euler) form - illustrate withexamples.

COURSE CONTENTUnit-IAlgebra1. Logarithms:

Definition of logarithm and its properties, natural and commonlogarithms; the meaning of e and exponential function, logarithmas a function and its graphical representation.

2. Partial Fractions:Rational, proper and improper fractions of polynomials.Resolving rational fractions in to their partial fractions coveringthe types mentioned below:

i) ( )

( )( )( )f x

x a x b x c ii) 2

( )( ) ( )( )

f xx a x b x c

iii) 2( )

( )( )f x

x a x b iv) 2 2

( )( )( )

f xx a x b

39

Matrices:3. Definition of matrix, types of matrices-examples, algebra of

matrices-equality of two matrices, sum, scalar multiplicationand product of matrices. Transpose of a matrix, Symmetric,skew-symmetric matrices-Minor, cofactor of an element-Determinant of a square matrix-Laplace's expansion, propertiesof determinants. Singular and non-singular matrices-Adjoint andmultiplicative inverse of a square matrix- examples-System oflinear equations in 3 variables-Solutions by Cramer's rule, Matrixinversion method-examples-Elementary row operations onmatrices -Gauss-Jordan method to solve a system ofequations.

Unit-IITrigonometry:4. Compound angles: Formulas of sin (A±B), cos (A±B), tan

(A±B), cot (A±B) and related identities with problems.5. Multiple and sub-multiple angles: trigonometric ratios of

multiple angles 2A, 3A and submultiple angle A/2 with problems.6. Transformations of products into sums or differences and vice

versa simple problems7. Inverse trigonometric functions: definition, domains and

ranges-basic properties- problems.8. Properties of triangles: relation between sides and angles

of a triangle- sine rule, cosine rule, tangent rule and projectionrule - statements only.

9. Hyperbolic functions: Definitions of hyperbolic functions,identities of hyperbolic functions, inverse hyperbolic functionsand expression of inverse hyperbolic functions in terms oflogarithms.

10. Complex Numbers: Definition of a complex number, Modulusand conjugate of a complex number, Arithmetic operations oncomplex numbers, Modulus- Amplitude (polar) form,Exponential (Euler) form of a complex number- Problems.

Reference Books:1. A text book of matrices by Shanti Narayan,2. Plane Trigonometry, by S.L Loney

*****

40

ENGINEERING PHYSICS-ISubject Title : Engineering Physics - ISubject Code : MET-103Periods per week : 04Total periods per semester: 60


No Periods of Marks Type Type(2 marks) (10 marks)

1. Units and Dimensions 08 08 4 -

2. Modern Physics 12 28 4 2

3. Heat and Thermo-dynamics 12 28 4 2

4. Elements of Vectors 14 28 4 2

5. Kinematics 14 28 4 2

TOTAL 60 120 20 8

INTERNAL ASSESSMENTUNIT TEST 1 : UNITS 1,2 and 3

UNIT TEST 2 : UNITS 4 and 5

OBJECTIVESUpon completion of the course the student shall be ableto

1.0 Understand the concept of Units and dimensions1.1 Explain the concept of Units1.2 Define the terms

a) Physical quantity, b) Fundamental physical quantitiesand c) Derived physical quantities

1.3 Define unit1.4 Define fundamental units and derived units1.5 State SI units with symbols

1.6 State Multiples and submultiples in SI system

1.7 State Rules of writing S.I. units

41

1.8 State advantages of SI units1.9 Define Dimensions1.10 Write Dimensional formulae1.11 Derive dimensional formulae of physical quantities1.12 List dimensional constants and dimensionless quantities1.13 State the principle of Homogeneity of Dimensions1.14 State the applications of Dimensional analysis (without

problems)1.15 State the limitations of dimensional analysis

2.0 Understand the concept of Modern physics2.1 Explain Photo-electric effect2.2 Write Einstein's photoelectric equation2.3 State the laws of photoelectric effect2.4 Explain the Working of a photoelectric cell2.5 List the Applications of photoelectric effect2.6 Recapitulate refraction of light and its laws2.7 Define critical angle2.8 Explain the Total Internal Reflection2.9 Explain the basic principle of optical Fiber2.10 Mention types of optical fibbers2.11 List the applications of optical Fiber2.12 Define super conductor and superconductivity2.13 List the examples of superconducting materials2.14 List the applications of superconductors

3.0 Understand the concept of Heat and thermodynamics3.1 Explain the concept of expansion of gases3.2 Explain Boyle's law3.3 State Charle's laws in terms of absolute temperature3.4 Define absolute zero temperature3.5 Explain absolute scale of temperature

42

3.6 Define ideal gas3.7 Derive the ideal gas equation.3.8 Define gas constant and Universal gas constant3.9 Explain why universal gas constant is same for all gases3.10 State SI unit of universal gas constant3.11 Calculate the value of universal gas constant3.12 State the gas equation in terms of density3.13 Distinguish between r and R3.14 Define Isothermal process3.15 Define adiabatic process3.16 Distinguish between isothermal and adiabatic process3.17 State first and second laws of thermodynamics3.18 Define specific heats & molar specific heats of a gas3.19 Derive the relation Cp - Cv = R3.20 Solve the related numerical problems

4.0 Understand the concept of Elements of Vectors4.1 Explain the concept of Vectors4.2 Define Scalar and Vector quantities4.3 Give examples for scalar and vector quantities4.4 Represent a vector graphically4.5 Classify the Types of Vectors4.6 Resolve the vectors4.7 Determine the Resultant of a vector by component method4.8 Represent a vector in space using unit vectors ( i, j, k )4.9 State triangle law of addition of vectors

4.10 State parallelogram law of addition of vectors

4.11 Illustrate parallelogram law of vectors in case of flyingbird and sling.

4.12 Derive an expression for magnitude and direction ofresultant of two vectors

43

4.13 State polygon law of addition of vectors

4.14 Explain subtraction of vectors

4.15 Define Dot product of two vectors with examples (Workdone, Power)

4.16 Mention the properties of Dot product

4.17 Define Cross products of two vectors and state formulaefor torque and linear velocity

4.18 Mention the properties of Cross product.

4.19 Solve the related numerical problems

5.0 Understand the concept of Kinematics5.1 Write the equations of motion in a straight line

5.2 Explain the acceleration due to gravity

5.3 Derive expressions for vertical motion

a) Maximum Height, b) time of ascent, c) time of descent,and d) time of flight

5.4 Derive an expression for height of a tower when a bodyprojected vertically upwards from the top of a tower.

5.5 Explain projectile motion with examples

5.6 Explain Horizontal projection

5.7 Derive an expression for the path of a projectile inhorizontal projection

5.8 Explain Oblique projection

5.9 Derive an expression for the path of projectile in Obliqueprojection

5.10 Derive formulae for projectile in Oblique projection

a) Maximum Height, b) time of ascent, c) time of descent,d) time of flight e) Horizontal Range and f) Maximumrange


44

COURSE CONTENT1. U n its an d D im en sio n s: Introduction - Physical quantity -

Fundamental and Derived quantities - Fundamental and Derivedunits- SI units -Multiples and Sub multiples - Rules for writingS.I. units-Advantages of SI units - Dimensions and Dimensionalformulae- Dimensional constants and Dimensionlessquantities- Principle of Homogeneity- Applications andlimitations of Dimensional analysis.

2. Modern Physics: Photoelectric effect -Einstein's photoelectricequation-laws of photoelectric effect - photoelectric cell -Applications of photo electric effect- Total internal reflection-fiber optics- -principle of an optical fiber-types of optical fibers- Applications of optical fibers- concepts of super conductivity -applications

3. Heat and Thermodynamics: Expansion of Gases- Boyle's law-Absolute scale of temperature- Charle's laws- Ideal gasequation- Universal gas constant- Differences between r andR- Isothermal and adiabatic processes- Laws ofthermodynamics- Specific heats of a gas - Problems

4. Elements of Vectors: Scalars and Vectors -Types of vectors(Proper Vector, Null Vector, Unit Vector, Equal , Negative Vector,Like Vectors, Co-Initial Vectors, Co-planar Vectors and PositionVector). Addition of vectors- Representation of vectors-Resolution of vectors - Parallelogram, Triangle and Polygonlaws of vectors-Subtraction of vectors- Dot and Cross productsof vectors-Problems

5. Kinematics: Introduction- Concept of acceleration due togravity- Equations of motion for a freely falling body and for abody thrown up vertically- Projectiles- Horizontal and Obliqueprojections- Expressions for maximum height, time of flight,range - problems

REFERENCE BOOKS1. Intermediate physics Volume- I & 2 Telugu Academy2. Text book of physics Resnick & Halliday3. Engineering physics Gaur and Gupta4. Fundamental Physics Volume -1 & 2 K.L.Gomber and

K.L.Gogia*****

45

ENGINEERING CHEMISTRY AND ENVIRONMENTALSTUDIES - I

Subject Title : Engineering Chemistry andEnvironmental Studies - I

Subject Code : MET-104Periods per week : 04Total periods per semester: 60



1. Fundamentals ofChemistry 18 40 5 3

2. Solutions 10 18 4 1

3. Acids & Bases 10 18 4 1

4. Water Technology 14 28 4 2

5. Environmental Studies-I 08 16 3 1

Total: 60 120 20 8


A. ENGINEERING CHEMISTRY1.0 Fundamentals of Chemistry1.1 Explain the fundamental particles of an atom like electron, proton

and neutron etc.,

1.2 Explain the concept of atomic number and mass number

1.3 State the Postulates of Bohr's atomic theory and its limitations

1.4 Explain the concept of Quantum numbers with examples

1.5 Explain 1.Aufbau's principle, 2.Hund's rule and 3.Pauli'sexclusion principle with examples.

1.6 Define Orbital.

1.7 Draw the shapes of s, p and d Orbitals.

46

1.8 Distinguish between Orbit and Orbital

1.9 Write the electronic configuration of elements up to atomicnumber 30

1.10 Define chemical bond.

1.11 Explain the Postulates of Electronic theory of valency

1.12 Define and explain three types of Chemical bonding viz., Ionic,Covalent, Coordinate covalent bond with examples.

1.13 Explain bond formation in NaCl and MgO

1.14 List the Properties of Ionic compounds

1.15 Explain covalent bond formation in Hydrogen molecule, Oxygenmolecule, and Nitrogen molecule using Lewis dot method.

1.16 List the Properties of Covalent compounds

1.17 Distinguish between ionic compounds and covalentcompounds.

1.18 Define the terms 1.Oxidation, 2.Reduction 3.Oxidation number4. Valency, with examples.

1.19 Calculate the Oxidation Number

1.20 Differentiate between Oxidation Number and Valency.

2.0 Solutions2.1 Define the terms 1.Solution, 2.Solute and 3.Solvent

2.2 Classify solutions based on physical state.

2.3 Define solubility, unsaturated, saturated and super saturatedsolutions.

2.4 Define mole.

2.5 Explain Mole concept with examples.

2.6 Define the terms 1. Atomic weight, 2. Molecular weight and 3.Equivalent weight

2.7 Calculate Molecular weight and Equivalent weight of Acids,Bases and Salts.

2.8 Define 1.Molarity and Normality.

2.9 Solve Numerical problems on Mole, Molarity and Normality

47

3.0 Acids and bases3.1 Explain Arrhenius theory of Acids and Bases

3.2 State the limitations of Arrhenius theory of Acids and Bases

3.3 Explain Bronsted - Lowry theory of acids and bases.

3.4 State the limitations of Bronsted - Lowry theory of acids andbases.

3.5 Explain Lewis theory of acids and bases

3.6 State the limitations of Lewis theory of acids and bases

3.7 Explain the Ionic product of water

3.8 Define pH and explain Sorenson scale

3.9 Solve the Numerical problems on pH (Strong Acids and Bases)

3.10 Define buffer solution and give examples.

3.11 State the applications of buffer solutions.

4. 0 Water Technology4.1 State the various Sources of water.

4.2 Define the terms soft water and hard water with examples

4.3 Define hardness of water.

4.4 Explain temporary and permanent hardness of water.

4.5 List the usual chemical compounds causing hardness (withFormulae)

4.6 Define Degree of hardness, units of hardness in ppm (mg/L)and numerical problems related to hardness.

4.7 Disadvantages of using hard water in industries.

4.8 Explain the methods of softening of hard water: a) permutitprocess b).Ion-Exchange process.

4.9 Essential qualities of drinking water.

4.10 Explain municipal treatment of water for drinking purpose.

4.11 Define Osmosis and Reverse Osmosis(RO).

4.12 List the advantages of RO

48

5.0. ENVIRONMENTALSTUDIES5.1 Define the term environment

5.2 Explain the scope and importance of environmental studies

5.3 Define and understand the following terms 1) Lithosphere,2) Hydrosphere, 3) Atmosphere, 4) Biosphere, 5) Pollutant,6) Contaminant 7) Pollution 8)receptor 9)sink 10) particulates,11) Dissolved oxygen (DO), 12) Threshold limit value (TLV),13).BOD and 14).COD

5.4 Explain the growing energy needs

5.5 Explain renewable (non-conventional) and non renewable(conventional) energy sources with examples.

5.6 Define an Ecosystem. Understand biotic and abioticcomponents of ecosystem.

5.7 Define the terms:

1) Producers, 2) Consumers and 3) Decomposers withexamples.

5.8 Explain biodiversity and threats to biodiversity

COURSE CONTENTA. ENGINEERING CHEMISTRY1. Fundamentals of Chemistry

Atomic Structure: Introduction - Fundamental particles -Bohr's theory - Quantum numbers - Aufbau principle - Hund'srule - Pauli's exclusion Principle- Orbitals, shapes of s, p and dorbitals - Electronic configurations of elements

Chemical Bonding: Introduction - Valency, types of chemicalbonds - Ionic, covalent and co-ordinate covalent bond withexamples - Properties of Ionic and Covalent compounds

Oxidation-Reduction: Concepts of Oxidation-Reduction,Oxidation Number- calculations.

2. SolutionsIntroduction-concentration methods - Mole concept, Molarity,

49

Normality, Equivalent weights, Numerical problems on Mole,Molarity and Normality

3. Acids and BasesIntroduction - theories of acids and bases and limitations -Arrhenius theory-Bronsted -Lowry theory - Lewis acid basetheory - Ionic product of water - pH and related numericalproblems - buffer solutions -Applications.

4. Water TechnologyIntroduction -soft and hard water - causes of hardness - typesof hardness -disadvantages of hard water - degree of hardness(ppm) - softening methods - permutit process - ion exchangeprocess - numerical problems related to degree of hardness -drinking water - municipal treatment of water for drinkingpurpose - Osmosis, Reverse Osmosis - advantages ofReverse osmosis

5. Environmental StudiesIntroduction - environment -scope and importance ofenvironmental studies important terms - renewable and nonrenewable energy sources - Concept of ecosystem, producers,consumers and decomposers - Biodiversity, definition andthreats to Biodiversity.

INTERNAL ASSESSMENTUNIT TEST 1 : UNITS 1 and 2

UNIT TEST 2 : UNITS 3,4 and 5

REFERENCE BOOKS1. Intermediate chemistry Vol 1&2Telugu Acedemy

2. Engineering Chemistry Jain & Jain

3. Engineering Chemistry O.P. Agarwal, Hi-Tech.

4. Engineering Chemistry Sharma

5. Engineering Chemistry A.K. De

*****

50

MINERAL PROCESSING TECHNOLOGY - ISubject Title : Mineral Processing

Technology - ISubject Code : MET-105Periods per week : 04Total periods per semester: 60



1 Ores & Ore Dressing 10 22 6 1

2 Ore Sampling 14 28 4 2

3 Comminution 20 42 6 3

4 Sizing 16 28 4 2

TOTAL 60 120 20 8

OBJECTIVESAfter the completion of course the student should be able to

comprehend the following:

1.0 Ores & ore dressing1.1 Define Native Metal, Mineral, Ore & Ore Dressing.

1.2 Know the minerals of commercially important Metals such asIron, Al, Cu, Zn, Mg, Ti, U, Th, Pb, Sn.

1.3 Know the metal content & chemical composition of the mineralsof the above Metals.

1.4 Know the advantages of mineral / ore dressing.

1.5 State the Important operations of ore Processing.

2.0 Ore Sampling2.1 State the need for study of ore sampling.

2.2 Define sample & sampling.

2.3 State the rules for sampling.

51

2.4 Classify the sampling processes.

2.5 List the types of hand sampling methods.

2.6 Explain Grab, Trench, pipe sampling, coning & Quartering andFractional selections.

2.7 Explain the principle of mechanical sampling.

2.8 Explain the working principle of Vezin sampler.

3.0 Comminution3.1 Define Comminution & State the objectives of Comminution.

3.2 Classify the Comminution processes.

3.3 State the principles of crushing.

3.4 Classify the crushing operations.

3.5 Explain the working principle & operation of Blake & DodgeJaw Crushers.

3.6 Explain the working principle & operation of roll crusher.

3.7 Define 'Angle of NIP' of roll crusher.

3.8 Derive an equation for angle of NIP.

3.9 Define grinding & Compare crushing and grinding.

3.10 Classify the Grinding Mills.

3.11 Explain the working principle & operation of Spherical andConical Ball Mill.

3.12 State the Laws of Comminution - Rittinger's, Kick's and Bond'slaws.

4.0 Sizing4.1 Understand the importance of sizing.

4.2 Know the sizing Methods.

4.3 Define screening & Classify screening surfaces.

4.4 Define Mesh number & Mesh Size.

4.5 Know designating the Mesh numbers as Per ISI.

4.6 Explain the method of making screen analysis by Rotap sieveshaker.

52

4.7 Tabulate the results of screen analysis by direct plot &cumulative plot methods.

4.8 Know the types of Industrial screens.

4.9 State the equation for capacity of screens.

4.10 Know the factors affecting the capacity of screens.

COURSE CONTENTS

1.0 ORES AND ORE DRESSING: Definition of native metal,mineral, ore & ore dressing, minerals of commercially importantmetals, metal content and chemical composition of theimportant ores, advantages of ore dressing., importantoperations of ore dressing.

2.0 ORE SAMPLING: Introduction of sampling. Rules for sampling.Classification of sampling. Hand sampling methods. Principleof Mechanical sampling.

3.0 COMMINUTION: Introduction - stages of crushing, primarycrushing: Blake type jaw crusher and Dodge crusher.Secondary crushing: working of Roll crusher. Angle of Nip ofRoll crusher. Grinding: Definition & classification of Ball mills.Working of Ball mills. Comparison of crushing & grinding. Lawsof Comminution.

4.0 SIZING: Introduction - sizing methods- screening types- meshsize & mesh number- ISI Designation of mesh number-screenanalysis by Rotap sieve shaker -tabulation of results-capacityof screen and effecting factors.

REFERENCE BOOKS1. Principles of Mineral Dressing - Gaudin

2. Elements of metallurgy - Dr.Swaroop

3. Ore Dressing - S.K. Jain

4. Non-Ferrous extractive Metallurgy - Ray. Abraham and Sridhar.

*****

53

ELEMENTS OF METALLURGICAL ENGINEERING -ISubject Title : Elements of Metallurgical

Engineering -ISubject Code : MET-106Periods per week : 04Total periods per semester: 60



1 Introduction toMetallurgy 18 24 2 2

2 Ferrous, Non Ferrousmetals and their Alloys 20 48 9 3

3 ManufacturingProcesses 22 48 9 3

TOTAL 60 120 20 8

OBJECTIVESAfter the completion of course the student should be able tocomprehend the following:

1.0 Introduction to metallurgy.1.1 Define material and classify them.1.2 Define metal and state its properties.1.3 Classify the metals.1.4 Define metallurgy and state its importance.1.5 Classify the divisions of metallurgy and explain them.1.6 State the economic importance of metallurgical Industries.1.7 List out important metal extraction plants in India. a) Integrated Iron & steel plants, b) Aluminum plants, c) Copper

plants, d) Zinc & lead plants.2.0 Ferrous, Non-Ferrous Metals and their alloys2.1 State the basic classification of plain carbon steels.2.2 List out the applications of the steels.

54

2.3 State the need for alloying the steel with other elements.2.4 State the composition, properties and industrial applications of

alloy steels.2.5 Know the properties of tool steels2.6 Know the composition and properties of high speed tool steels.2.7 Know the composition of special cutting materials like stellites,

cemented carbides2.8 Know the classification of cast irons - Gray, white, malleable,

spheroidal- composition, properties and applications.2.9 Know the need for non-ferrous metals and their alloys in

engineering application.2.10 List out the composition, properties, and industrial application

of the important-Non-ferrous alloys like brass, bronze, muntzmetal.

2.11 Know the properties of bearing metals.3.0 Manufacturing Processes:3.1 Know about melting process.3.2 Know the different furnaces used for melting like Cupola,

Reverberatory, Induction, Arc furnaces.3.3 Define casting.3.4 Know the basic steps involved in sand casting3.5 State rolling operation.3.6 Know about different types of rolling mills.3.7 State the principle of forging3.8 Know the types of forging hammers and presses, open die

forging, closed die forging3.9 Know the extrusion process by direct method and by indirect

method.3.10 Know about different drawing processes- Rod drawing, wire

drawing, deep drawing.3.11 Know about powder metallurgy process and the basic steps

involved - Production of metal powders, Powder mixing,sintering compacting of powders into shapes,

3.12 State the applications of powder metallurgy

55

COURSE CONTENTS1.0 INTRODUCTION TO METALLURGY: Materials

classification, metal properties &classification, divisions ofmetallurgy, economic importance of metallurgical industries,important metal extraction plants in India.

2.0 FERROUS, NON FERROUS METALS AND THEIRALLOYS: Classification of steels and their applications. Needfor alloying steels, different alloy steels - their properties,applications. Properties of tool steels, Properties andcomposition of high speed tool steel, Composition of specialcutting steels - stellites and cemented carbides. Different castirons - gray, white, malleable, spheroidal - composition,properties and their applications. Important non ferrous metalsbrass, bronze, muntz metals - their compositions, propertiesand applications. Properties of bearing metals.

3.0 MANUFACTURING PROCESSES: Melting process, differentfurnace used for melting - cupola, reverberatory, induction, arc.,Definition of casting, sand casting processes - Rollingoperation, different rolling mills, Principle of forging, differenttypes of forging hammers and press ,smith forging and closeddie forging .Process of extrusion by direct method and indirectmethod., Different drawing processes - rod drawing,wiredrawing, deep drawing., Powder metallurgy processes :production of metal powders, powder mixing ,sintering andcompacting of powders into shapes., Powder metallurgyapplications.

REFERENCE BOOKS1. Elements of metallurgy - Dr.Swaroop

2. Non-Ferrous extractive Metallurgy - Ray. Abraham and Sridhar

3. Physical Metallurgy Principles and Practice - V Raghavan

4. Physical metallurgy - Sydney H Avner

5. Powder Metallurgy - A K Sinha.

*****

56

ENGINEERING DRAWING - ISubject Title : Engineering Drawing - ISubject Code : MET-107Periods per week : 06Total periods per semester: 90

TIME SCHEDULES. Major Topics No. of Periods Weightage Short Essay

No Drawing of Marks Answer TypePlates Questions Questions

1 Importance ofEngineeringDrawing -- 01 - - -

2 EngineeringDrawingInstruments 01 05 - - -

3 Free handlettering &Numbering 01 06 05 1 -

4 DimensioningPractice 01 09 05 1 -

5 Geometricalconstructions 03 24 25 1 02

6 Projection ofpoints, Lines,Planes & Solids 03 21 25 1 02

7 Sectional views 03 24 20 - 02

Total 12 90 80 04 06

The Course is aimed at developing basic graphic skills so asto enable them to use these skills in preparation of engineeringdrawings, their reading and interpretation

OBJECTIVESUpon completion of the subject the student shall be able to

1.0 Understand the basic concepts of Engineering Drawing1.1 State the importance of drawing as an engineering

communication medium.

57

1.2 State the necessity of B.I.S. Code of practice for EngineeringDrawing.

1.3 Explain the linkages between Engineering drawing and othersubjects of study in diploma course.

2.0 Use of Engineering Drawing Instruments2.1 Select the correct instruments and draw lines of different

orientation.

2.2 Select the correct instruments and draw small and large Circles.

2.3 Select the correct instruments for measuring distances on thedrawing.

2.4 Use correct grade of pencil for different types of lines, thicknessand given function.

2.5 Select and use appropriate scales for a given application.

2.6 Identify different drawing sheet sizes as per I.S. and StandardLayouts.

2.7 Prepare Title block as per B.I.S. Specifications.

2.8 Identify the steps to be taken to keep the drawing clean andtidy.

Drawing Plate 1: (Having Four exercises)3.0 Write Free Hand Lettering and Numbers3.1 Write titles using sloping lettering and numerals of 7mm, 10mm

and 14mm height

3.2 Write titles using vertical lettering and numerals of 7mm, 10mmand 14mm height

3.3 Select suitable sizes of lettering for different layouts andapplications

3.4 Practice the use of lettering stencils.

Drawing plate 2: (Having 5 to 6 exercises)

4.0 Understand Dimensioning Practice4.1 Define "Dimensioning.

4.2 State the need of dimensioning the drawing according toaccepted standard.

58

4.3 Identify notations of Dimensioning used in dimensioned drawing.

4.4 Identify the system of placement of dimensions in the givendimensioned drawing.

4.5 Dimension a given drawing using standard notations anddesired system of dimensioning.

4.6 Dimension standard features applying necessary rules.

4.7 Arrange dimensions in a desired method given in a drawing.

4.8 Identify the departures if any made in the given dimensioneddrawing with reference to SP-46-1988, and dimension thesame correctly.

Drawing Plate 3: (Having 8 to10 exercises)

5.0 Apply Principles of Geometric Constructions5.1 Divide a given line into desired number of equal parts internally.

5.2 Draw tangent lines and arcs.

5.3 Use General method to construct any polygon.

5.4 Explain the importance of conics

5.5 Construct conics (ellipse, parabola and hyperbola) by generalmethod

5.6 Construct ellipse by concentric circles method

5.7 Construct parabola by rectangle method

5.8 Construct rectangular hyperbola from the given data.

5.9 Construct involute from the given data.

5.10 Construct cycloid and helix from the given data.

5.11 State the applications of the above constructions in engineeringpractice.

Drawing Plate -4: Having problems up to construction of polygon

Drawing Plate -5: Having problems of construction of conics

Drawing Plate -6: Having problems of construction of involute,cycloid and helix

6.0 Apply Principles of Projection of points, lines, planes &solids

59

6.1 Visualize the objects

6.3 Explain the I-angle and III-angle projections

6.3 Practice the I-angle projections

6.4 Draw the projection of a point with respect to reference planes(HP&VP)

6.5 Draw the projections of straight lines with respect to tworeference

Planes (up to lines parallel to one plane and inclined to otherplane)

6.6 Draw the projections of planes (up to planes perpendicular toone plane and inclined to other plane)

6.7 Draw the projections of solids (up to axis of solids parallel toone plane and inclined to other plane)

Drawing Plate -7: Having problems up to projection of pointsand Lines (15 exercises)

Drawing Plate -8: Having problems of projection of planes (6exercises)

7.0 Appreciate the need of Sectional Views7.1 Explain the need to draw sectional views.

7.2 Select the section plane for a given component to revealmaximum information.

7.3 Explain the positions of section plane with reference planes

7.4 Differentiate between true shape and apparent shape of section

7.5 Draw sectional views and true sections of regular solidsdiscussed in 6.0

7.6 Apply principles of hatching.

Drawing Plate- 9: Having problems of section of solids (6exercises)

Drawing Plate-10: Having problems of section of solids (6exercises)

60

Competencies and Key competencies to be achieved by thestudent

S.No Major topic Key Competency1. Importance of Engineering Explain the linkages

Drawing between Engineering drawingand other subjects of study inDiploma course.

2. Engineering Drawing Select the correct instrumentsInstruments to draw various entities in

different orientation

3. Free hand lettering Write titles using sloping and& Numbering vertical lettering and numerals

as per B.I.S (Bureau of Indianstandards)

4. Dimensioning Practice Dimension a given drawingusing standard notations anddesired system ofdimensioning

5. Geometrical construction Construct ellipse, parabola,rectangular hyperbola,involute, cycloid and helixfrom the given data.

6. Projection of points, Lines, Draw the projection of a point,Planes & Solids straight lines, planes & solids

with respect to referenceplanes (HP& VP)

7. Sectional views Differentiate between trueshape and apparent shape ofsection

Use conventional represen-tation of Engineering materialsas per B.I.S. Code.

Apply principles of hatching.

Draw simple sections ofregular solids

61

COURSE CONTENTNOTE

1. B.I.S Specification should invariably be followed in all thetopics.

2. A-3 Size Drawing Sheets are to be used for all DrawingPractice Exercises.

1.0 The importance of Engineering Drawing

Explanation of the scope and objectives of the subject ofEngineering Drawing Its importance as a graphiccommunication -Need for preparing drawing as per standards- SP-46 -1988 - Mention B.I.S - Role of drawing in -engineeringeducation - Link between Engineering drawing and othersubjects of study.

2.0 Engineering drawing Instruments

Classifications: Basic Tools, tools for drawing straight lines,tools for curved lines, tools for measuring distances and specialtools like mini drafter & drafting machine - Mentioning of namesunder each classification and their brief description -Scales:Recommended scales reduced & enlarged -Lines: Types oflines, selection of line thickness - Selection of Pencils -SheetSizes: A0, A1, A2, A3, A4, A5, Layout of drawing sheets in respectof A0, A1, A3 sizes, Sizes of the Title block and its contents,Care and maintenance of Drawing Sheet, Drawing plate:

Lay out of sheet - as per SP-46-1988 to a suitable scale.

Simple Exercises on the use of Drawing Instruments.Importance of Title Block.

3.0 Free hand lettering & numbering

Importance of lettering - Types of lettering -Guide Lines forLettering.

Practicing of letters & numbers of given sizes (7mm, 10mmand 14mm).

Advantages of single stroke or simple style of lettering - Use oflettering stencils.

62

4.0 Dimensioning practicePurpose of engineering Drawing, Need of B.I.S code indimensioning -Shape description of an Engineering object -Definition of Dimensioning size description -Location offeatures, surface finish, fully dimensioned Drawing - Notationsor tools of dimensioning, dimension line extension line, leaderline, arrows, symbols, number and notes, rules to be observedin the use of above tools -Placing dimensions: Aligned systemand unidirectional system (SP-46- 1988)-Arrangement ofdimensions Chain, parallel, combined progressive, anddimensioning by co-ordinate methods-The rules fordimensioning standard, features "Circles (holes) arcs, angles,tapers, chamfers, and dimension of narrow spaces.

5.0 Geometric ConstructionDivision of a line: to divide a straight line into given number ofequal parts internally examples in engineering application.

Construction of tangent lines: to draw tangent lines touchingcircles internally and externally.

Construction of tangent arcsi) To draw tangent arc of given radius to touch two lines inclined

at given angle (acute, right and obtuse angles).

ii) Tangent arc of given radius touching a circle or an arc and agiven line.

iii) Tangent arcs of radius R, touching two given circles internallyand externally.

Construction of polygon: Construction of any regular polygonof given side length using general method.

Conical Curves: Explanation of Ellipse, Parabola, Hyperbola,as sections of a double cone and a loci of a moving point,Eccentricity of above curves - Their Engg.application viz.Projectiles, reflectors, P-V Diagram of a Hyperbolic process,Construction of any conic section of given eccentricity bygeneral method.

Construction of ellipse by concentric circles method.

Construction of parabola by rectangle method.

63

Construction of rectangular hyperbola

General Curves: Involute, Cycloid and Helix, explanations aslocus of a moving point, their engineering application, viz, Geartooth profile, screw threads, springs etc. - their construction

6.0 Projection of points, lines and planes & solidsProjecting a point on two planes of projection -Projecting a pointon three planes of projection -Projection of straight line.

(a) Parallel to both the planes.

(b) Perpendicular to one of the planes.

(c) inclined to one plane and parallel to other planes

Projection of regular planes(a) Plane perpendicular to HP and parallel to VP and vice versa.

(b) Plane perpendicular to HP and inclined to VP and vice versa.

Projection of regular solids(a) Axis perpendicular to one of the planes

(b) Axis parallel to VP and inclined to HP and vice versa.

7.0 Sectional viewsNeed for drawing sectional views - what is a sectional view -Location of cutting plane - Purpose of cutting plane line -Selection of cutting plane to give maximum information (verticaland offset planes) - Hatching - Section of regular solids inclinedto one plane and parallel to other plane

REFERENCE BOOKSEngineering Graphics by P I Varghese - ( McGraw-hill)

Engineering Drawing by Basant Agarwal & C.M Agarwal - (McGraw-hill)

Engineering Drawing by N.D.Bhatt.

T.S.M. & S.S.M on " Technical Drawing" prepared by T.T.T.I.,Madras.

SP-46-1998 - Bureau of Indian Standards.

*****

64

BASIC WORKSHOP PRACTICE - ISubject Title : Basic Workshop Practice - ISubject Code : MET-108Periods per week : 06Periods per year : 90

TIMESCHEDULES.No Major Title Noof Periods1 Carpentry 30

2 Forging 30

3 Fitting 30

Total 90

OBJECTIVESCarpentry1. Practice on planning, sawing and chiselling.2. Prepare a half lap joint.3. Prepare a Dovetail joint.4. Prepare a Mortise joint.5. Prepare a 20 cm x 15cm teak wood switch board with hinges

and bottom hook.6. Fix the laminate sheet to the above box and cut suitable holes

to mount one flush type switch, socket.FORGING SHOP1 Conversion of Round to square.2 Conversion of Round to Hexagon.3 Preparation of Chisel from round rod.4 Preparation of ring and hook from M.S. Round.5 Preparation of a hexagonal bolt and nut.Fitting1 Marking and chipping on Mild - steel flat 12 mm thick.2 Cutting with hack saw, M.S. Flats of 6 mm thick.3 Marking, cutting, drilling, Chamfering and tapping on a M.S. Flat

12 mm thick.4 Assembling of two pieces, Matching by filing (6 mm thick M.S.

Plate)5. Cut a G.I pipe and solid rod using hack saw.6. Thread cutting of G.I. pipe, metal conduit and solid rod using

die set

65

KEY competencies to be achieved by the student Carpentry

Title of the Job

Practice on planning,sawing andchipping

Prepare a half lap joint

Prepare a Dovetail joint

Prepare a Mortise joint

Prepare a 20cmX 15 cm teak woodswitch board with hinges and bottomhook

Fix the laminate sheet to the abovebox and cut suitable holes to mountflush type switch, socket

Key Competency

Identify dimensions of thejob(LXBXW)Planning and surface finishing usingjack planner.Based on measurement sawing orcutting.Chipping(removal of excess materialor internal cutting)

Planning using metal jack planer orwooden jack planer.Cutting using hand saw or cross cutsaw.Chiseling(measurement of centerportion)Smoothening the surface using raspfile.Joint would be square shape.

Planning using metal jack planer.Cutting using cross cut saw.Chiseling with the help of mallet.Joint would be in this shape \_/

Dimensions of teak wood job25*45*150mm of 2 pieces.Measurement of appropriatedimensions using mortise gauge.

Prepare wooden box of dimensions20*15cms. Planning, cutting, andchiseling. Mark appropriate Handdrills to produce holes.

7. Internal thread cutting using tap set and cleaning the threadsusing reamers and make a hexagonal nut from a round rod.

66

Title of the Job

Conversion of Round to Square

Conversion of Round to Hexagon

Preparation of a Chisel from round rod

Preparation of a ring and hook fromM.S round

Preparation of a hexagonal bolt andnut

Key Competency

• Heat the specimen to theappropriate temperature

• Identify the holding and strikingtools

• Hammer the specimen to therequired shape












• Upset the cylindrical rod• Hammer the specimen to the

required shape

FORGING SHOP

67

Title of the Job

Marking and Chipping on Mild steelflat of 12 mm thick

Cutting with hack saw of MS flats of6mm thick

Marking, Cutting, drilling, chamferingand tapping on a MS flat of 2 mm thick

Assembling of two pieces, matchingby filing

Key Competency

• Identify appropriate measuringtool

• Handle appropriate marking tool• Handle appropriate chipping tool• Mark the dimensions• Remove the material by chipping

from MS flats• Use the hack saw while cutting

MS flats

• Load and unload hack saw bladefrom its frame

• Locate the hole on M.S. plate• Identify appropriate drill bit• Load and unload drill bit from the

machine• Identify appropriate taps• State the specifications of taps

and drill• Tap the hole

• Identify appropriate file• State the specifications of a fileFile the specimen

FITTING SHOP

68

PHYSICS LAB PRACTICE - I(Common for all branches)

Subject Title : Physics Lab Practice- ISubject Code : MET-109Periods per week : 03Total periods per semester: 22

TIME SCHEDULES.No Name of the Experiment No. of

Periods1. Hands on practice on Vernier Calipers 03

2. Hands on practice on Screw gauge 03

3. Verification of Parallelogram law of forcesand Triangle law of forces 03

4. Boyle's law verification 03

5. Refractive index of solid using travelingmicroscope 03

6. Meter bridge 03

Revision 02

Test 02

Total: 22

OBJECTIVESUpon completion of the course the student shall be able to

1.0 Practice the Vernier caliper to determine the volume of acylinder and sphere

2.0 Practice the Screw gauge to determine thickness of a glassplate and cross section of a wire

3.0 Verify the parallelogram law and Triangle law of forces.

4.0 Verify the Boyle's law employing a Quill tube

69

5.0 Determine the refractive index of a solid using travellingmicroscope

6.0 Determine the specific resistance of wire material using MeterBridge

Name of theExperiments (No. of

Periods)

1. Hands on practiceon Vernier Calipers(03)

2. Hands on practiceon Screw gauge(03)

3. Verif ication ofParallelogram lawof forces andTriangle law offorces (03)

4. Boyle's lawverification (03)

Competencies

Find the Least countFix the specimen inpositionRead the scalesCalculate the volume ofgiven object

Find the Least countFix the specimen inpositionRead the scales Calculate thickness ofglass plate and crosssection of wire

Fix suitable weightsNote the positions ofthreads on drawingsheetFind the angle atequilibrium pointC o n s t r u c tparallelogramCompare themeasured diagonalConstruct triangleFind the length of sidesCompare the ratios

Note the atmosphericpressure

Key competencies

Read the scalesCalculate thevolume of givenobject

Read the scalesC a l c u l a t ethickness of givenglass plateCalculate crosssection of wire

Find the angle atequilibrium pointConstructingparallelogramConstruct triangleCompare theratios of force andlength

Find the length of


70

Fix the quill tube to retortstandFind the length of aircolumnFind the pressure ofenclosed airFind and compare thecalculated value P x l

Find the least count ofvernier on microscopePlace the graph paperbelow microscopeRead the scaleCalculate the refractiveindex of glass slab

Make the circuitconnectionsFind the balancinglengthCalculate unknownresistanceFind the radius of wireCalculate the specificresistance

air columnFind the pressureof enclosed airFind the value P xl

Read the scaleCalculate therefractive index ofglass slab

Find the balancinglengthC a l c u l a t eu n k n o w nresistanceCalculate thespecific resistance

5. Refractive index ofsolid using trav-eling microscope(03)

6. Meter bridge (03)

71

CHEMISTRY LAB PRACTICE - I(Common for all branches)

Subject Title : Chemistry Lab Practice- ISubject Code : MET-110Periods per week : 03Total periods per semester: 22


Periods1. Familiarization of methods of Volumetric

Analysis 03

2. Preparation of Std Na 2CO3 solution andmaking solutions of different dilution 03

3. Estimation of HCl solution using Std.Na2CO3 solution 03

4. Estimation of NaOH using Std. HCl solution 03

5. Estimation of H2SO4 using Std. NaOHsolution 03

6. Estimation of Mohr's Salt using Std. KmnO4 03

Revision 02

Test 02

Total: 22

Objectives:Upon completion of the course the student shall be able to

1.0 Practice volumetric measurements (using pipetts, measuringjars, volumetric flask, burettes) and gravimetric measurements(using different types of balances), making dilutions, etc.

2.0 Practice making standard solutions with pre weighted salts andto make desired dilutions using appropriate techniques.

72

3.0 Conduct titrations adopting standard procedures and using Std.Na2 CO3 solution for estimation of HCl

4.0 Conduct titrations adopting standard procedures and using Std.HCl solution for estimation of NaOH

5.0 Conduct titrations adopting standard procedures and using Std.NaOH solution for estimation of H2SO4

6.0 Conduct titrations adopting standard procedures and using Std.KmnO4 solution for estimation of Mohr's Salt


Periods)

Familiarization ofmethods for Volume-tric analysis (03)

Preparation of StdNa2CO3 and makingsolutions of differentdilution (03)

Estimation of HClsolution using Std.Na2CO3 solution (03)Estimation of NaOHusing Std. HCl solution(03)Estimation of H2SO4using Std. NaOHsolution (03)

Competencies

--

Weighing the salt to theaccuracy of .01 mgMeasuring the water withvolumetric f lask,measuring jar, volumetricpipette and graduatedpipetteMaking appropriatedilutions

Cleaning the glasswareand rinsing withappropriate solutionsMaking standardsolutionsMeasuring accurately thestandard solutions andtitrantsFilling the burette withtitrant

Key competencies

--

Weighing the saltto the accuracy of.01 mgMeasuring thewater withvolumetric flask,measuring jar,volumetric pipetteand graduatedpipetteMaking appro-priate dilutions

Making standardsolutionsM e a s u r i n gaccurately thestandard solutionsand titrantsE f f e c t i v e l yControlling the flowof the titrant


73

Estimation of Mohr'sSalt using Std.KMnO4 (03)

Fixing the burette to thestandEffectively Controlling theflow of the titrantIdentifying the end pointMaking accurateobservationsCalculating the results

Identifying the endpointMaking accurateobservations

74

COMPUTER FUNDAMENTALS LAB PRACTICE -1(Common to All Branches)

Subject Title : Computer Fundamentals LabPractice- 1

Subject Code : MET- 111Periods/Week : 03Periods/Semester : 45

LIST OF EXPERIMENTS1.0 BASICS1.1. Identify the various components of a Computer system

1.2. Differentiate between hardware and software components

1.3. State the configuration of a computer system

1.4. Exercise on creation of Text Files using Notepad, WordPad

1.5. Exercise on creation of .jpeg, .bmp Files using MS-Paint

1.6. Exercise how to use calculator

2.0 DOS Operating System2.1. Practice on Internal and External commands.

2.2. Create and use Batch Files.

2.3. Know the usage of Editors.

3.0 WINDOWS Operating System3.1. Exercise on creation of folders and organizing files in different

folders

3.2. Exercise on use of Recycle Bin

3.3. Exercise on use of My Computer and My Documents

3.4. Exercise on creation of shortcut to files and folders (in otherfolders) on Desktop

3.5. Exercise on arranging of icons - name wise, size, type, Datemodified

75

3.6. Exercise on searching of files and folders

3.7. Exercise on using of explorer for accessing of files and folders

3.8. Exercise on organizing files / folders using copy and paste

3.9. Change resolution, colour, appearance, screen server optionsof Display

3.10. Change the system date and time.

4.0 INTERNET4.1. Importance of web browser software

4.2. Structure of URL

4.3. Create an e-mail account

4.4. Send an e-mail

4.5. Receive an e-mail

4.6. Browse the Internet using various search engines.

*****

76

OBJECTIVES AND KEY COMPETENCIESS.No. Name of the

Experiments

1. Identify the vari-ous componentsof a Computersystem

2. Differentiate bet-ween hardwareand softwarecomponents

3. State the con-figuration of ac o m p u t e rsystem

4. Practice on Inter-nal and Externalcommands.

5. Create and useBatch Files.

6. Know the usageof edlin Editor

Objectives

Identify variousComponents of aSystem

To Differentiatebetween hardwareand softwarecomponents

Able to observeconfiguration of givensystem

To use internalcommandsTo use Externalcommands

Able to create BatchfilesAble to createautoexe.bat file

Able to use edlincommand to create afileAble to edit a file usingedlin command

Key Competencies

Check whethercomponents areidentified correctlyIdentify all componentsinside computerIdentify all PeripheralsconnectedObserve the functionalityof all components likeCPU, RAM, HDD, FDD,Motherboard

Observe differencesbetween hardware andsoftware components

Use System icon incontrol panelUse system informationin Accessories

Check whether able touse all internalcommands using DOSCheck whether able touse all externalcommands using DOS

Check whether able tocreate by taking set filesin creating batch fileCheck whether able tocreate autoexe.bat fileproperly

Check whether able touse edlin command inDOS environmentCheck whether able toedit a file using edlincommand

77

7. Exercise oncreation of foldersand organizingfiles in differentfolders

8. Exercise oncreation of .jpeg,.bmp Files usingMS Paint

9. Exercise on usingRecycle Bin

10. Exercise on use ofMy Computer andMy Documents

Able to create folderAble to organize file indifferent folders

Able to create picturefile in .jpeg formatAble to create picturefile in .bmp format

Able to Use Recycle Bin

Able to Access files andfolders in C: DriveAble to Access files andfolders in other drivesAble to use MyDocuments so thatorganize and accessfiles and folders in itAble to use MyDocuments so thatOrganizing files in MyMusic, My Pictures, MyVideos Able to create short cutfor My Documents ondesktop properly

Check whether able tocreate folder using rightclick on desktopCheck whether able tocreate folder usingwindows explorerObserver in organizingfiles in different foldersusing windows explorerObserver in organizingfiles in different foldersusing My Computer

Check whether able tocreate picture file .jpegformat properlyCheck whether able tocreate picture file in .bmpformat properly

Check Recycle binwhether able to usedelete filesObserve files wereproperly restored files

Check whether able toaccess files in C: Driveusing My Computercorrectly or notCheck whether able toaccess files in otherdrives using MyComputer correctly or notCheck whether able useCD/DVD drive using MyComputerCheck whether able toorganize fi les andfolders in My DocumentsCheck Whether able toorganize fi les in MyMusic, My Pictures, MyVideos in My DocumentsCheck able to createshort cut for MyDocuments on desktopproperly

78

11. Exercise on crea-tion of shortcut tofiles and folders(in other folders)on Desktop

12. Exercise onarranging oficons - namewise, size, type,Date modi-fied

13. Exercise on sear-ching of files andfolders

14. Exercise on usingof explorer foraccessing of filesand folders

15. Exercise on orga-nizing files /folders usingcopy and paste

16. Exercise usingCalculator fromAccessories andthrough Run

17. Exercise on shutdown of computersystem

18. Exercise on understanding the useof Taskbar

19. Exercise on usingof Internet Explo-rer or any otherbrowser

Able to create shortcutof files and folders ondesktop

Able to arranging oficons - name wise,size, type, Datemodified on desktop

Able to search of filesand folders

Able to use of explorerfor accessing of filesand folder

Able to organizing files/ folders using copyand paste

Able to use calculatorin Standard modeAble to use calculatorin Scientific mode

Able to shutdown ofcomputer system

Able to understand theuse of Taskbar byopening someapplications

Able to use of InternetExplorerAble to use of MozillaFirefoxAble to use of GoogleChromeAble to use of opera

Check whether can ableto create shortcut for anyfiles created on desktopCheck whether can ableto create shortcut for anyfolder created ondesktop

Observe whether able toarrange of icons - namewise, size, type, Datemodified

Check searching of filesand folders

Check use of explorer foraccessing of files andfolders

Check organizing files /folders using copy andpaste

Check calculator inStandard modeCheck calculator inScientific mode

Check shutdown ofcomputer system

Check the use ofTaskbar by openingsome applications

Check use of InternetExplorerCheck use of MozillaFirefoxCheck use of GoogleChromeCheck use of opera

79

Check resolution,colour, appearance,screen server options ofDisplay

Check change systemdate and time

Check able to create ane-mail account

Check able to send ane-mail

Check able to receive ane-mail

Check able to search fora content in the Internetusing various searchengines

20. Change resol-ution, color,a p p e a r a n c e ,screen serveroptions of Display

21. Change thesystem date andtime

22. Create an e-mailaccount

23. Send an e-mail

24. Receive an e-mail

25. Browse theInternet usingvarious searchengines

Able to changeresolution, colour,appearance, screenserver options ofDisplay

Able to change systemdate and time

Able to create an e-mailaccount

able to send an e-mail

able to receive an e-mail

Able to search for acontent in the Internetusing various searchengines

80

II SEMESTER

81


SCHEME OF INSTRUCTIONS AND EXAMINATIONII SEMESTER


/Week Semester


Hours Marks Marks

THEORY

MET-201 English- II 3 - 45 3 20 80 100

MET-202 EngineeringMathematics-II 5 - 75 3 20 80 100

MET-203 EngineeringPhysics-II 4 - 60 3 20 80 100

MET-204 EngineeringChemistry andEnvironmentalStudies-II 4 - 60 3 20 80 100

MET-205 Mineral ProcessingTechnology-II 4 - 60 3 20 80 100

MET-206 Elements of MetallurglcalEngineering -II 4 - 60 3 20 80 100

PRACTICALS

MET-207 EngineeringDrawing-II - 6 90 3 40 60 100

MET-208 Basic Work ShopPractice-II - 6 90 3 40 60 100

MET-209 Physics LabPractice-II - 3 45 3 20 30 50

MET-210 Chemistry LabPractice-II 20 30 50

MET-211 ComputerFundamentalsLab Practice-II - 3 45 3 40 60 100

TOTAL 24 18 630 -- 280 720 1000

82

ENGLISH-II(Common to All the Branches)

Second SemesterSubject Title : English - IISubject Code : MET-201Periods per week : 03Total periods per semester: 45


No Periods of Marks Type TypeQuestions Questions

1. Speaking 10 26 8 1

2. Grammar (IncludingL6 Adjectives, L/Prepositions) 14 24 12 -

3. Reading 6 20 - 2

4. Writing 15 50 - 5

Total 45 120 20 8

OBJECTIVES AND KEY COMPETENCIESS.No. Name of Unit01 E x p r e s s i n g

Obligations

02 Fixing and Can-celling Appoint-ments

03 Extending andA c c e p t i n gInvitations

ObjectivesExpress obligationsExpress an order or astrong suggestion

Fix appointmentsReschedule or cancelappointments

Extend invitationsAccept invitations

Key CompetenciesLearn the words toexpress suggestionsand obligationsExpress suggestionsand obligations

Know the importance ofappointmentLearn expressions usedin fixing an appointmentKnow the ways of re-scheduling and can-celling appointments

Identify the phrasesused to extend andaccept invitationsPractise a few ways ofextending invitationsLearn the expressionsused for acceptinginvitations

83

04 Giving Instruc-tions

05 Asking for andGiving Directions

06 Describing Words

07 The Here andNow

08 An Environmen-tal Challenge

09 The Will toSucceed

10 Waiting for Mr.Clean

Understand instruc-tionsGive instructions

Ask for directionsGive directions

Listen for generalcomprehensionListen for specif icdetailsidentify adjectives andknow what an adjectiveis use adjectivesaccurately

Listen for generalcomprehensionListen for specif icdetailsidentify preposit ionsand understand whatprepositions areUse prepositions

Comprehend the mainideaLearn new words

Understand the mainideaLearn narrative style ofwriting

Understand the mainideaIdentify conversational

Know the need to giveinstructionsLearn the steps involvedin giving instructionsPractise givinginstructions

Know the words andphrases used often ingiving directionsLearn how to ask for andgive directionsKnow the common errorsin giving directions

Listen for main idea andminute detailsLearn several adjectivesKnow the common errorsin the use of adjectives

Listen for main idea andminute detailsLearn the prepositions ofplaceLearn the prepositions oftimeLearn the commonerrors in the use ofprepositions

Learn how to identify thecentral ideaLearn some new words

Know the secret ofsuccess of a womanentrepreneurKnow the narrative styleof writingLearn new words

Learn to note down thecentral idea of aparagraph

84

style of writingLearn new words

Understand whatreported speech isReport somethingspoken by others

Identify commonerrors in sentencesCorrect errors in theusage of nouns,pronouns and verbs

Identify the errors inusage of EnglishCorrect errors in theusage of articles,adjectives, adverbs,prepositions andconjunctions

Correct errors invocabulary, questions,subject-verb agree-ment, homophonesIdentify errors ofredundancy

Study and understandthe information in flowchartsanalyse/interpret flowchartsWrite a paragraphusing the data given

Understand theinformation in a treediagramAnalyse the dataWrite a paragraphusing the data given

Learn new words

Learn two ways ofreporting a speaker'swordsLearn how to changefrom direct speech toindirect speech

Know the various errorsin spoken and writtenEnglishIdentify the commonerrorsCorrect the errors innouns, pronouns andverbs

Correct the errors in theusage of articles,adjectives, adverbs,prepositions andconjunctionsRewrite a paragraphcorrecting the errors

Correct the errors in theusage of vocabulary andin framing questionsCorrect the errors inconcord and redundancy

Study the data given inflow chartsanalyse the data given inflow chartsWrite a paragraph usingthe data given

Study the data given intree diagramsanalyse the data given intree diagramsWrite a paragraph usingthe data given

11 Reported Speech

12 Error Analysis- I

13 Error Analysis - II

14 Error Analysis - III

15 Data Interpre-tation - I

16 Data Interpre-tation - II

85

Study the data given intablesanalyse the data given intablesWrite a paragraph usingthe data given

Learn the salientfeatures of a resumeObserve a sampleresume givenPrepare a resume

Know the importance ofa cover letterRead the sample coverletterWrite a cover letter

Know the importance ofmaking notesLook for the key wordsgiven in the textObserve the sampleoutline using cue methodMake notes using cueand mapping methods

Learn the various kindsof reportsObserve the format of areport of an industrialvisitLearn the tips to write areportWrite a report

17 Data Interpre-tation - III

18 Resume

19 Cover Letter

20 Note Making

21 Writing a Report

Understand the data inthe tablePresent the data givenin a tableWrite a paragraphusing he data given

Understand what aresume isPreparea resume

Understand what acover letter isWrite a cover letter

Identify importantwords and ideas in atextLearn how to makenotes using the cuemethod

Understand the formatof a report of anindustrial visitWrite a report using theformat

86

ENGINEERING MATHEMATICS - II(Common to all branches)

Subject title : Engineering Mathematics-IISubject code : MET-202Periods per week : 05Total Periods per Semester: 75


S. Major Topic No of Periods Weightage Short Type Essay Type No of Marks

Unit - I Theory Practice R U App R U App

Co-ordinateGeometry

1 Straight Lines 6 2 13 2 2 0 0 1/2 0

2 Circle 6 2 13 2 2 0 0 1/2 0

Unit -II DifferentialCalculus

3 Limits and Continuity 6 2 10 2 3 0 0 0 0

4 Differentiation 20 10 48 2 2 0 2 2 0

Unit -IIIApplications ofDifferentiation

5 GeometricalApplications 8 3 19 2 0 0 0 1/2 1

6 Maxima and Minima 7 3 17 1 0 0 0 1/2 1

Total 53 22 120 11 9 0 2 4 2

Marks 22 18 0 30 30 20




87

ENGINEERING MATHEMATICS - IICOMMON TO ALL BRANCHES

ObjectivesUpon completion of the course the student shall be able to:

UNIT - ICoordinate Geometry1.0 Solve the problems on Straight lines1.1 Write the different forms of a straight line - point slope form,

two point form, intercept form, normal form and general form

1.2 Solve simple problems on the above forms

1.3 Find distance of a point from a line, acute angle between twolines, intersection of two non-parallel lines and distance betweentwo parallel lines.

2.0 Solve the problems on Circles2.1 Define locus of a point - circle and its equation.

2.2 Find the equation of a circle given

(i) Center and radius

(ii) Two ends of a diameter

(iii) Centre and a point on the circumference

(iv) Three non-collinear points

(v) Centre and tangent

2.3 Write the general equation of a circle and find the Centre andradius.

2.4 Write the equation of tangent and normal at a point on the circle.

2.5 Solve the problems to find the equations of tangent and normal.

UNIT - IIDifferential Calculus3.0 Use the concepts of Limit and Continuity for solving the

problems

88

3.1 Explain the concept of limit and meaning of lim ( )x a

f x l

and

state the properties of limits.

3.2 Mention the Standard limits

limn n

x a

x ax a

,

0

sinlimx

xx

, 0

tanlimx

xx

, 0

1limx

x

ax

,

0

1limx

x

ex

,

1

0lim (1 ) xx

x

, 1lim 1

x

x x

(All without proof).

3.3 Solve the problems using the above standard limits

3.4 Evaluate the limits of the type 2

2limx l

a x b x cx x

and

( )lim( )x

f xg x

3.5 Explain the concept of continuity of a function at a point and onan interval with some examples whether a given function iscontinuous or not.

4.0 Appreciate Differentiation and its meaning in engineeringsituations

4.1 State the concept of derivative of a function y = f(x) - definition,

first principle as 0

( ) ( )limh

f x h f xh

and also provide

standard notations to denote the derivative of a function.

4.2 State the significance of derivative in scientific and engineeringapplications.

4.3 Find the derivatives of elementary functions like xn , ax, ex, logx, sin x, cos x, tanx, Secx, Cosecx and Cot x using the firstprinciples.

4.4 Find the derivatives of simple functions from the first principle.

4.5 State the rules of differentiation of sum, difference, scalar

89

multiplication, product and quotient of functions with illustrativeand simple examples.

4.6 Explain the method of differentiation of a function of a function(Chain rule) with illustrative examples such as

(i) 2 2tt

(ii) 2 sin 2x x (iii) 2 1

x

x (iv) log sin(cos )x

4.7 Find the derivatives of Inverse Trigonometric functions andexamples using the Trigonometric transformations.

4.8 Explain the method of differentiation of a function with respectto another function and also differentiation of parametricfunctions with examples.

4.9 Find the derivatives of hyperbolic functions.

4.10 Explain the procedures for finding the derivatives of implicitfunction with examples.

4.11 Explain the need of taking logarithms for differentiating somefunctions with examples like [f(x)]g(x).

4.12 Explain the concept of finding the higher order derivatives ofsecond and third order with examples.

4.13 Explain the concept of functions of several variables, partialderivatives and difference between the ordinary and partialderivatives with simple examples.

4.14 Explain the definition of Homogenous function of degree n

4.15 Explain Euler's theorem for homogeneous functions withapplications to simple problems.

UNIT - IIIApplications of the Differentiation5.0 Understand the Geometrical Applications of Derivatives5.1 State the geometrical meaning of the derivative as the slope of

the tangent to the curve y=f(x) at any point on the curve.

5.2 Explain the concept of derivative to find the slope of tangentand to find the equation of tangent and normal to the curvey=f(x) at any point on it.

90

5.3 Find the lengths of tangent, normal, sub-tangent and sub normalat any point on the curve y=f(x).

5.4 Explain the concept of angle between two curves andprocedure for finding the angle between two given curves withillustrative examples.

6.0 Use Derivatives to find extreme values of functions6.1 Define the concept of increasing and decreasing functions.

6.2 Explain the conditions to find points where the given function isincreasing or decreasing with illustrative examples.

6.3 Explain the procedure to find the extreme values (maxima orminima) of a function of single variable - simple problemsyielding maxima and minima.

6.4 Solve problems on maxima and minima in applications likefinding areas, volumes, etc.

COURSE CONTENTUNIT-ICoordinate geometry1. Straight lines: various forms of straight lines, angle between

lines, perpendicular distance from a point, distance betweenparallel lines-examples.

2. Circle: locus of a point, Circle definition-Circle equation given(i) center and radius, (ii) two ends of a diameter (iii) Centre anda point on the circumference (iv) three non collinear points and(v) Centre and tangent equation - general equation of a circle- finding center, radius: tangent, normal to circle at a point on it.

UNIT-IIDifferential Calculus3. Concept of Limit- Definition- Properties of Limits and Standard

Limits -Simple Problems-Continuity of a function at a point-Simple Examples only.

4. Concept of derivative- definition (first principle)- differentnotations-derivatives of elementary functions - problems.

91

Derivatives of sum, product, quotient, scalar multiplication offunctions - problems. Chain rule, derivatives of inversetrigonometric functions, derivative of a function with respect toanother function, derivative of parametric functions, derivativeof hyperbolic, implicit functions, logarithmic differentiation -problems in each case. Higher order derivatives - examples -functions of several variables - partial differentiation, Euler'stheorem-simple problems.

UNIT-IIIApplications of Derivatives:5. Geometrical meaning of the derivative, equations of Tangent

and normal to a curve at any point. Lengths of tangent, normal,sub tangent and subnormal to the curve at any point. Anglebetween the curves - problems.

6. Applications of the derivative to find the extreme values -Increasing and decreasing functions, finding the maxima andminima of simple functions - problems leading to applicationsof maxima and minima.

REFERENCE BOOKS:1. Co-ordinate Geometry, by S.L Loney.

2. Thomas Calculus, Pearson Addison-Wesley publishers.

3. Calculus - I, by Shanti Narayan and Manicavachgam Pillai, S.VPublications.

*****

92

ENGINEERING PHYSICS-IISubject Title : Engineering Physics - IISubject Code : MET-203Periods per week : 04Total periods per semester: 60



1. Friction 08 14 2 1

2. Work, Power and Energy 10 18 4 1

3. Simple Harmonic Motion 12 28 4 2

4. Sound 12 26 3 2

5. Properties of matter 06 06 3 -

6. Electricity & magnetism 12 28 4 2

Total: 60 120 20 8




1.0 Understand the concept of Friction1.1 Define friction and state its causes

1.2 Classify the types of friction

1.3 Explain the concept of Normal reaction

1.4 State the laws of friction

1.5 Define coefficients of friction

1.6 Explain the Angle of friction

1.7 Derive an expression for acceleration of a body on arough horizontal surface

93

1.8 Derive an expression for the displacement and time takento come to rest over a rough horizontal surface

1.9 List the Advantages and Disadvantages of friction

1.10 Mention the methods of minimizing friction


2.0 Understand the concept of Work, Power, and Energy2.1 Define the terms Work, Power and Energy.

2.2 State SI units and dimensional formula for Work, Power,and Energy

2.3 Define potential energy

2.4 Derive an expression for Potential energy with examples

2.5 Define kinetic energy

2.6 Derive an expression for kinetic energy with examples

2.7 State and prove Work- Energy theorem

2.8 Explain the relation between Kinetic energy andmomentum

2.9 State the law of conservation of energy

2.10 Verify the law of conservation of energy in the case of afreely falling body


3.0 Understand the concept of Simple harmonic motion3.1 Define Simple harmonic motion

3.2 State the conditions of Simple harmonic motion

3.3 Give examples for Simple harmonic motion

3.4 Show that the tip of the projection of a body moving incircular path with uniform speed is SHM

3.5 Derive an expression for displacement of a bodyexecuting SHM

3.6 Derive an expression for velocity of a body executing SHM

3.7 Derive an expression for acceleration of a body executingSHM

94

3.8 Derive expressions for Time period and frequency of SH M

3.9 Define phase of S H M

3.10 Derive expression for Time period of a simple pendulum

3.11 State the laws of simple pendulum

3.12 Explain seconds pendulum


4.0 Understand the concept of Sound4.1 Define the term sound

4.2 Explain longitudinal and transverse wave motion

4.3 Distinguish between musical sound and noise

4.4 Explain noise pollution and state SI unit for noise

4.5 Explain causes of noise pollution

4.6 Explain effects of noise pollution

4.7 Explain methods of minimizing noise pollution

4.8 Explain the phenomenon of beats

4.9 List the applications of beats

4.10 Define Doppler effect

4.11 List the Applications of Doppler effect

4.12 Explain reverberation and reverberation time

4.13 Write Sabine's formula

4.14 Explain echoes

4.15 State conditions of a good auditorium


5.0 Understand the properties of matter5.1 Define terms Elasticity and plasticity

5.2 Define the terms stress and strain

5.3 State the units and dimensional formulae for stress andstrain

95

5.4 State the Hooke's law

5.5 Define the surface tension

5.6 Explain Surface tension with reference to molecular theory

5.7 Define angle of contact

5.8 Define capillarity and state examples

5.9 Write the formula for surface tension based on lgebraic t

5.10 Explain the concept of Viscosity

5.11 Provide examples for surface tension and Viscosity

5.12 State Newton's formula for viscous force

5.13 Define co-efficient of viscosity

5.14 Explain the effect of temperature on viscosity of liquidsand gases

5.15 State Poiseulle's equation for Co-efficient of viscosity


6.0 Understand the concept of Electricity and Magnetism6.1 Explain the concept of Electricity

6.2 State the Ohm's law

6.3 Explain the Ohm's law

6.4 Define specific resistance, conductance and their units

6.5 State Kichoff's laws

6.6 Explain Kichoff's laws

6.7 Describe Wheatstone's bridge with legible sketch

6.8 Derive an expression for balancing condition ofWheatstone's bridge

6.9 Explain the basic concept of Meter Bridge with legiblesketch

6.10 Explain the concept of magnetism

6.11 State the Coulomb's inverse square law of magnetism

6.12 Define magnetic field and magnetic lines of force

96

6.13 State the Magnetic induction field strength-units anddimensions

6.14 Describe the moment of couple on a bar magnet placedin a uniform magnetic field


COURSE CONTENT1. Friction:

Introduction to friction- Causes- Types of friction- Laws offriction -Angle of friction- Motion of a body over a horizontalsurface- Advantages and disadvantages of friction- Methodsof reducing friction - Problems

2. Work, Power and Energy:Work, Power and Energy- Definitions and explanation- potentialenergy- kinetic energy-Derivations of Potential and Kineticenergies-K.E and Momentum relation - Work-Energy theorem-Law of Conservation of energy- Problems

3. Simple Harmonic Motion:Introduction- Conditions of SHM- Definition- Examples-Expressions for displacement, velocity, acceleration, Timeperiod, frequency and phase in SHM- Time period of a simplependulum- Laws of simple pendulum-seconds pendulum-Problems

4. Sound:Sound- Nature of sound- Types of wave motion - Musical soundand noise- Noise pollution - Causes & effects- Methods ofreducing noise pollution- Beats- Doppler effect- Echo-Reverberation-Reverberation time-Sabine's formula-Conditionof good auditorium- Problems

5. Properties of matterDefinition of Elasticity -Definition of stress and strain -the unitsand dimensional formulae for stress and strain-The Hooke'slaw- Definition of surface tension-Explanation of Surface tensionwith reference to molecular theory - Definition of angle of

97

contact - Definition of capillarity -The formula for surface tensionbased on capillarity - Explanation of concept of Viscosity -Examples for surface tension and Viscosity - Newton's formulafor viscous force- Definition of co-efficient of viscosity- The effectof temperature on viscosity of liquids and gases - Poiseulle'sequation for Co-efficient of viscosity- The related numericalproblems

6. Electricity & Magnetism:Ohm's law and explanation- Specific resistance- Kirchoff'slaws- Wheatstone's bridge - Meter bridge- Coulomb's inversesquare law- magnetic field- magnetic lines of force-Magneticinduction field strength-moment of couple-problems.

REFERENCE BOOKS1. Intermediate physics Volume- I & 2 Telugu Academy

2. Text book of physics Resnick & Halliday

3. Engineering physics Gaur and Gupta

4. Fundamental Physics Volume -1 & 2 K.L.Gomberand K.L.Gogia

*****

98

ENGINEERING CHEMISTRY AND ENVIRONMENTALSTUDIES - II

Subject Title : Engineering Chemistry andEnvironmental Studies-II




1. Principles of Metallurgy 10 16 3 1

2. Electro Chemistry 14 30 5 2

3. Corrosion 08 16 3 1

4. Polymers 12 28 4 2

5. Fuels 06 12 1 1

6. Environmental Studies-II 10 18 4 1

Total: 60 120 20 8


1. 0 Principles of Metallurgy1.1 List the Characteristics of Metals.1.2 Distinguish between Metals and Non Metals1.3 Define the terms 1.Mineral, 2.Ore, 3. Gangue, 4. Flux and 5.

Slag1.4 Describe Froth Floatation method of concentration of ore.1.5 Describe the methods involved in extraction of crude metal-

Roasting, Calcination and Smelting.1.6 Explain the purification of Metals by Electrolytic Refining1.7 Define an Alloy1.8 Write the Composition of the following alloys:1.Brass, 2.German

silver, and Nichrome

99

1.9 List the uses of following Alloys: Brass, German silver, Nichrome2.0 Electro chemistry2.1 Define the terms1. Conductor, 2. Insulator, 3.Electrolyte and

4.Non - electrolyte2.2 Types of electrolytes.- strong and weak with examples.2.3 Distinguish between metallic conductors and Electrolytic

conductors.2.4 Explain Arrhenius theory of electrolytic dissociation2.5 Explain electrolysis of fused NaCl.2.6 Explain Faraday's laws of electrolysis2.7 Define Chemical equivalent, Electrochemical equivalent.2.8 Solve the Numerical problems based on Faraday's laws of

electrolysis2.9 Define Galvanic cell2.10 Explain the construction and working of Galvanic cell2.11 Distinguish between electrolytic cell and galvanic cell2.12 Explain the standard electrode potentials2.13 Define electrochemical series and explain its significance.2.14 Define and explain emf of a cell.2.15 Solve the numerical problems on emf of cell3.0 Corrosion3.1 Define the term corrosion3.2 Explain the Factors influencing the rate of corrosion3.3 Explain the concept of electrochemical theory of corrosion3.4 Describe the formation of a) composition cell, b) stress cell c)

concentration cell3.5 Define rust and explain the mechanism of rusting of iron with

chemical reactions.3.6 Explain the methods of prevention of corrosion: a) Protective

coatings b) Cathodic protection (Sacrificial anode process andImpressed - voltage process)

4.0 Polymers4.1 Explain the concept of lgebraic tion4.2 Describe the methods of lgebraic tion a) addition lgebraic

tion b) condensation polymerization with examples.

100

4.3 Define the term plastic4.4 Types of plastics with examples.4.5 Distinguish between thermoplastics and thermosetting plastics4.6 List the Characteristics of plastics.4.7 State the advantages of plastics over traditional materials4.8 State the disadvantages of using plastics.4.9 Explain the methods of preparation and uses of the following

plastics:1. Polythene, 2. PVC, 3.Teflon, 4. Polystyrene 5. Ureaformaldehyde 6. Bakelite (only flow chart i.e. without chemicalequations).

4.10 Define the term natural rubber4.11 State the structural formula of Natural rubber4.12 Explain the processing of Natural rubber from latex4.13 List the Characteristics of natural rubber4.14 Explain the process of Vulcanization4.15 List the Characteristics of Vulcanized rubber4.16 Define the term Elastomer4.17 Describe the preparation and uses of the following synthetic

rubbers a) Butyl rubber, b) Buna-s and c) Neoprene rubber5.0 Fuels5.1 Define the term fuel5.2 Classify the fuels based on physical state - solid, liquid and

gaseous fuels with examples.5.3 Classify the fuels based on occurrence- primary and secondary

fuels with examples.5.4 List the characteristics of a good fuel.5.5 State the composition and uses of the following gaseous fuels:

a) water gas, b) producer gas, c) natural gas, d) coal gas,e) Bio gas and f) acetylene

6.0. ENVIRONMENTAL STUDIES6.1 Define air pollution6.2 Classify the air pollutants- based on origin and states of matter6.3 Explain the causes of air pollution

101

6.4 Explain the use and over exploitation of forest resources anddeforestation

6.5 Explain the effects of air pollution on human beings, plants andanimals

6.6 Explain the green house effect - ozone layer depletion and acidrain

6.7 Explain the methods of control of air pollution6.8 Define water pollution6.9 Explain the causes of water pollution6.10 Explain the effects of water pollution on living and non living

things6.11 Understand the methods of control of water pollution.

CONTENTS1. Principles of Metallurgy

Characteristics of Metals and distinction between Metals andNon Metals, Metallurgy, ore, Gangue, Flux, Slag - Concentrationof Ore -Froth floatation - Methods of Extraction of crude Metal -Roasting, Calcination, Smelting - Alloys - Composition and usesof Brass, German silver and Nichrome

2. ElectrochemistryConductors, insulators, electrolytes - Arrhenius theory ofelectrolytic dissociation - electrolysis - Faraday's laws ofelectrolysis- numerical problems - Galvanic cell - standardelectrode potential - electro chemical series -emf and numericalproblems on emf of a cell

3. CorrosionIntroduction - factors influencing the rate of corrosion -electrochemical theory of corrosion - composition, stress andconcentration cells- rusting of iron and its mechanism -prevention of corrosion by coating methods, cathodic protection

4. PolymersIntroduction - polymerization - types of polymerization - addition,condensation with examples - plastics - types of plastics -

102

advantages of plastics over traditional materials -Disadvantages of using plastics - preparation and uses of thefollowing plastics: 1. Polytehene 2. PVC 3. Teflon 4.Polystyrene 5. Urea formaldehyde 6. Bakelite - Rubber -Natural rubber - processing from latex -Vulcanization -Elastomers - Butyl rubber, Buna-s, Neoprene rubber and theiruses.

5. FuelsDefinition and classification of fuels - characteristics of goodfuel - composition and uses of gaseous fuels- a) water gas,b)producer gas, c) natural gas, d) coal gas, e) Bio gas and f)acetylene

6. ENVIRONMENTAL STUDIESAir pollution - causes-Effects - forest resources : uses andover exploitation, deforestation, acid rain, green house effect -ozone depletion - control of air pollution - Water pollution -causes - effects - control measures.



REFERENCEBOOKS1. Intermediate chemistry Vol 1&2Telugu Acedemy

2. Engineering Chemistry Jain & Jain

3. Engineering Chemistry O.P. Agarwal, Hi-Tech.

4. Engineering Chemistry Sharma

5. Engineering Chemistry A.K. De

*****

103

MINERAL PROCESSING TECHNOLOGY - IISubject Title : Mineral Processing Technology - IISubject Code : MET-205Periods / Week : 04Periods / Year : 60



1 Classification 16 24 4 2

2 Concentration 24 56 10 4

3 Concentration Processesof Some Important Ores 20 40 6 2

Total: 60 120 20 08

OBJECTIVESAfter the completion of course the student should be able tocomprehendthe following:

1.0 Classification1.1 Know the movement of solids in fluids - Principles of free settling

and hindered settling.

1.2 Know about Laminar and turbulent flow of fluids, ReynoldsNumber and its expression.

1.3 Know the principle of classification.

1.4 Know the mechanism of classification in relation to Stoke'slaw of settling.

1.5 Explain the working principle of Dorr rake classifier and ofhydrocyclone classifier

2.0 Concentration2.1 Define Concentration & State the objectives of Concentration.

2.2 State the principles of Concentration.

104

2.3 Define concentrate, tailing & middling.

2.4 Classify the concentration operations.

2.5 Explain the working principle of magnetic separator.

2.6 List the gravity concentration processes.

2.7 Explain the sink & float techniques.

2.8 Explain the working principle of tabling.

2.9 Explain the principle of jigging.

2.10 Explain the jigging process (Harz Jig only).

2.11 Define froth flotation.

2.12 Explain the flotation process.

2.13 Define the frother, collector, activator, depressor & conditionerwith suitable examples.

2.14 Explain the operation of Denver flotation cell.

2.15 Electrostatic separation -principle and operation.

3.0 Concentration processes of some important ores3.1 Know and explain the flow sheet of bauxite ore processing.

3.2 Know and explain the flow sheet of coal washing.

3.3 Know and explain the flow sheet of iron ore processing

3.4 Know and explain the flow sheet of gold ore processing.

3.5 Know and explain the flow sheet of lead/zinc concentration.

COURSE CONTENTS1.0 CLASSIFICATION

Introduction -movement of solids in fluids-free settling, hinderedsettling,laminar flow, turbulent flow, Reynolds number-derivation, principle ofclassification ,Stoke's law of settling -mechanism of classification,working principle of mechanicalclassifier Dorr's classifier and centrifugal classifier Hydrocyclone classifier.

105

2.0 CONCENTRATIONIntroduction-principles of concentration-Definitions ofconcentrate tailing& middling -concentration Methods-Magneticseparator- gravity concentration processes-sink & floattechnique, tabling, Jigging- frothflotation - process & additives.

3.0 CONCENTRATION OF SOME IMPORTANT ORESExplain about the processing of aluminum ore - bauxite - flowsheet, processing of coal- main operations and flow sheet, Mainconcentrationprocesses of iron ores - flow sheet, Floatation ofgold ores - flow Sheet. Concentration flow sheet of lead/zinc.

REFERENCE BOOKS1. Principles of Mineral Dressing - Gaudin

2. Elements of metallurgy - Dr.Swaroop

3. Ore Dressing - S.K. Jain

4. Non-Ferrous extractive Metallurgy - Ray. Abraham andSridhar.

*****

106

ELEMENTS OF METALLURGICAL ENGINEERING -IISubject Title : Elements of Metallurgical

Engineering -IISubject Code : MET-206Periods / Week : 04Periods / Year : 60



1 Principles of ExtractiveMetallurgy -Pyrometallurgy 22 48 9 3

2 Principles of ExtractiveMetallurgy -Hydrometallurgy 18 24 2 2

3 Principles of ExtractiveMetallurgy -Electrometallurgy 20 48 9 3

Total 60 120 20 08


1.0 Principles of extractive metallurgy - Pyrometallurgy1.1 State the salient features of extractive metallurgy

1.2 Define Pyrometallurgy& List the Pyrometallurgical operations.

1.3 Explain drying.

1.4 Explain calcination.

1.5 Define roasting & classify the roasting operation.

1.6 Explain oxidizing, blast, and sulphatise, Autogenous roastingwith chemical reactions.

1.7 Explain multiple hearth roaster, Flash roaster & fluidised BedRoaster.

107

1.8 Define smelting.

1.9 Define Flux, Slag and Matte.

1.10 C lassify smelting operations

a) Reduction Smelting - Carbothermic & Metallothermic

b) Matte Smelting.

1.11 State the importance of Coke as a reducing agent inCarbothermic Reduction

1.12 Define refining & State the purpose of refining.

1.13 List important methods of Refining.

1.14 Define Drossing & fire refining.

1.15 Explain Zone Refining.

2.0 Principles of extractive metallurgy - Hydrometallurgy2.1 Define Hydrometallurgy.

2.2 State the advantages & Limitations of Hydro Metallurgy.

2.3 List out the important stages in Hydro Metallurgy.

2.4 Define leaching & identify the materials for leaching.

2.5 State the properties of leachant.

2.6 List important Leaching operations.

2.7 Explain pressure, bacterial, ammonical, Acid & heap leaching.

2.8 Define precipitation.

2.9 Understand briefly the typical flow sheet of Hydrometallurgy.

3.0 Principles of extractive metallurgy - Electrometallurgy3.1 Define electrometallurgy.

3.2 State the advantages & Limitations of electrometallurgy

3.3 Classify Electro Metallurgical operations

3.4 Define Electrolysis.

3.5 State Faradays' laws of Electrolysis.

3.6 State the principle of electrolysis w.r.t. to Anodic &cathodicreactions.

108

3.7 Explain the electrolysis of molten salts.

3.8 Explain the electrolysis of aqueous solutions.

3.9 State Principle of electrolytic refining.

3.10 State applications of Electrolytic Refining.

3.11 State the Principle of Electro Plating.

3.12 State the commercial applications of electroplating.

COURSE CONTENTS1.0 PRINCIPLES OF EXTRACTIVE METALLURGY-

PYROMETALLURGY:Introduction- Types of pyro metallurgical operations- Drying,calcination and Roasting., Classification of roasting operationsMultiple hearth roaster, Flash Roaster & fluidised bed roaster.Smelting: Types of smelting-principle of Reduction smelting &Matte smelting Refining: Definition & purpose -Types of refining:Drossing, fire reefing & Zone refining

2.0 PRINCIPLES OF EXTRACTIVE METALLURGY-HYDROMETALLURGY:Introduction - leaching- properties of leachant -suitable Materialsfor leaching- types of leaching methods - precipitation-Typicalflow sheet of Hydro metallurgy.

3.0 PRINCIPLES OF EXTRACTIVE METALLURGY-ELECTROMETALLUGY:Introduction- electrolysis: Definition& principle- cathodic&anodic reactions of electrolysis Faraday's laws of electrolysis-electrolysis of molten salt &aqueous solutions- ElectrolyticRefining: principle & applications- Electro plating: principle&applications.

REFERENCE BOOKS1. Elements of metallurgy - Dr.Swaroop

2. Non-Ferrous extractive Metallurgy - Ray. Abraham and Sridhar.

*****

109

ENGINEERING DRAWING - IISubject Title : Engineering Drawing - IISubject Code : MET-207Periods per week : 06Total periods per semester: 90

TIME SCHEDULES. Major Topics No. of Periods Weightage Short Essay

No Drawing of Marks Answer TypePlates Questions Questions

1 Auxiliary views 01 06 10 1 ½

2 OrthographicProjection 03 33 25 1 2

3 Pictorial drawing 03 30 25 1 2

4 Development of surfaces 03 21 20 1 1½

Total 10 90 80 04 06

The Course is aimed at developing basic graphic skills so asto enable them to use these skills in preparation of engineeringdrawings, their reading and interpretation

Pre-Requisite: Clear visualization and sound pictorial intelligence


1.0 Understand the need of auxiliary views1.1 State the need of Auxiliary views for a given engineering

drawing.

1.2 Draw the auxiliary views of a given engineering component

1.3 Differentiate between auxiliary view and apparent view

Drawing plate No.1: (Having 4 exercises)

2.0 Apply principles of orthographic projection2.1 Explain the principles of orthographic projection with simple

sketches.

110

2.2 Draw the orthographic view of an object from its pictorialdrawing.

2.3 Draw the minimum number of views needed to represent agiven object fully.

Drawing Plate No. 2 : (Having 8 to 10 exercises)



3.0 Prepare pictorial drawings3.1 State the need of pictorial drawings.

3.2 Differentiate between isometric scale and true scale.

3.3 Prepare Isometric views for the given orthographic drawings.

Drawing plate No 5: (Having 10 to 12 exercises)

Drawing plate No. 6: (Having 10 to 12 exercises)

Drawing plate No. 7: (Having 10 to 12 exercises)

4.0 Interpret Development of surfaces of different solids4.1 State the need for preparing development drawing.

4.2 Prepare development of simple engineering objects (cubes,prisms, cylinders, cones, pyramid) using parallel line and radialline method.

11.3 Prepare development of surface of engineering componentslike trays, funnel, 900 elbow & rectangular duct.

Drawing plate No. 8: (Having 05 exercises)



111


S.No Major topic Key Competency1. Auxiliary views Draw the auxiliary views of a

given Engineering component

Differentiate between Auxiliaryview and apparent view

2. Orthographic Projection Draw the minimum number ofviews needed to represent agiven object fully.

3. Pictorial drawing Differentiate betweenisometric scale and truescale.

Draw the isometric views ofgiven objects,.

4. Development of surfaces Prepare development ofSurface of Engineeringcomponents like trays, funnel,900 elbow & rectangular duct.

COURSE CONTENTNOTE1. B.I.S Specification should invariably be followed in all the topics.

2. A-3 Size Drawing Sheets are to be used for all Drawing PracticeExercises.

1.0 Auxiliary viewsNeed for drawing auxiliary views -Explanation of the basicprinciples of drawing an auxiliary views explanation of referenceplane and auxiliary plane - Partial auxiliary view.

2.0 Orthographic ProjectionsMeaning of orthographic projection -Using a viewing box and amodel - Number of views obtained on the six faces of the box,- Legible sketches of only 3 views for describing object -Conceptof front view, top view, and side view sketching these views fora number of engg objects - Explanation of first angle projection.

112

- Positioning of three views in First angle projection -Projection of points as a means of locating the corners of thesurfaces of an object - Use of miter line in drawing a third viewwhen other two views are given -Method of representing hiddenlines -Selection of minimum number of views to describe anobject fully.

3.0 Pictorial DrawingsBrief description of different types of pictorial drawing viz.,Isometric, oblique, and perspective and their use - Isometricdrawings: Iso axis, angle between them, meaning of visualdistortion in dimensions - Need for an isometric scale, differencebetween Isometric scale, and ordinary scale differencebetween Isometric view and Isometric projection - Isometricand non-Isometric lines -Isometric drawing of common featureslike rectangles, circular - shapes, non-isometric lines - Use ofbox and offset methods

4.0 Development of SurfacesNeed for preparing development of surface with reference tosheet metal work -Concept of true length of a line with referenceto its orthographic projection when the line is (i) parallel to theplane of projection (ii) inclined to one principal and parallel tothe other -Development of simple solids like cubes, prisms,cylinders, cones, pyramid (sketches only) -Types ofdevelopment: Parallel line and radial line development -Procedure of drawing development, drawings of trays, funnels,900 elbow pipes and rectangular ducts.

REFERENCE BOOKSEngineering Graphics by P I Varghese - ( McGraw-hill)

Engineering Drawing by Basant Agarwal & C.M Agarwal - (McGraw-hill)

Engineering Drawing by N.D.Bhatt.

T.S.M. & S.S.M on " Technical Drawing" prepared by T.T.T.I.,Madras.

SP-46-1998 - Bureau of Indian Standards.

*****

113

BASIC WORKSHOP PRACTICE - IISubject Title : Basic Workshop Practice - IISubject Code : MET-208Periods / Week : 06Periods / Year : 90

TIME SCHEDULES.No. List of Experiments No. of Periods1 Machine shop 30

2 Welding 60

TOTAL 90

OBJECTIVESUpon completion of the course, the student shall be able to:

1. Machine shop1. Turn the given rod to get three different diameters using lathe.

2. Make a bolt and cut threads using lathe.

3. Cut the threads to G.I. pipe using lathe.

4. Prepare a centre punch and knurl its head.

5. Make a square plate using power hawk saw, remove sharpedges using grinder, mark triangle and drill three holes ofdifferent diameters at the vertices.

2. Welding1. Handle the gas welding torch for welding

2. Handle the Electrode Holder for laying welding beads.

3. Understand the operation of welding transformer and generator.

4. Perform various welding joint operations.

5. Perform spot welding operations.

*****

114

KEY competencies to be achieved by the student.Machine shop

Title of the Job

Turn the given rod to get threedifferent diameters using lathe

Make a bolt and cut threads usinglathe

Cut the threads to G.I. pipes usinglathe

Prepare a centre punch and knurl itshead

Make a square plate using powerhawk saw, remove sharp edgesusing grinder, mark triangle and drillthree holes of different diameters atthe vertices

Key Competency

25*100mm M.S Round Rod.Hold job in chuck.Marking, step turning.

16mm Rod (M.S)Holding, Marking, Threadingof11Tpa.

Cut Threads on Circumference of G.IPipe.20*100mm G.I Pipe.Align Job by Holding it in Chuck,Thread Cutting & Checking withScrew Gauge.

Manufacture of center punch onlathe.20*100mm M>S RoundPlain Turning, Taper, Knurling,Chamfering.

6mm Plate*50*50mm M.s Flat,Drilling Holes of Different Dia atVertices of Triangle.

115

Welding

Title of the Job

Handle the gas welding torch forwelding

Handle the Electrode holder forlaying welding beads

Understand the operation of weldingtransformer and generator

Perform various welding jointoperations

Perform spot welding operations

Key Competency

Study the various Parts of GasWelding/Equipment.Know the handling of Gas Torch &Cylinders.

Fix the Electrode in the Clamp.Perform the Welding operations.

Study the principle of WeldingTransformer/Generator.Know the working of Weldingtransformer/Generator.

Edge preparationHold the Electrode at suitable angle.Identify the suitable method ofWelding Techniques.Maintain proper distance betweenwork piece and electrode tip producearcCheck weld Bead.

Resistance welding is done for twooverlapping work pieces.

116

PHYSICS LAB PRACTICE - II(Common for all branches)

Subject Title : PHYSICS LAB PRACTICE- IISubject Code : MET-209Periods per week : 03Total periods per semester: 23


Periods1. Focal length and Focal power

of convex lens (Separate & Combination) 03

2. Simple pendulum 03

3. Velocity of sound in air -(Resonance method) 03

4. Surface tension of liquid using travelingmicroscope 03

5. Coefficient of Viscosity by capillary method 03

6. Mapping of magnet lines of force 03

Revision 03

Test 02

Total: 23


1.0 Determine the Focal length and focal power of convex lensesusing U-V and graphical method

2.0 Determine the value of acceleration due to gravity using SimplePendulum and verify with L-T2 graph.

3.0 Determine the velocity of sound in air at room temperature

117

4.0 Determine the surface tension of a liquid using travellingmicroscope

5.0 Determine the viscosity of a liquid using capillary method

6.0 Practice the mapping of magnetic lines of force.


Periods)

1. Focal length andFocal power ofconvex lens (Sepa-rate & Combina-tion) (03)

2. Simple pendulum(03)

3. Velocity of sound ina i r -Resonancemethod (03)

Competencies

Fix the object distanceFind the Image distanceCalculate the focal lengthand power of convex lensand combination ofconvex lensesDraw u-v and 1/u - 1/vcurves

Fix the simple pendulumto the standAdjust the length ofpendulumFind the time for numberof oscillationsFind the time periodCalculate theacceleration due togravityDraw l-T and l-T2 graph

Arrange the resonanceapparatusAdjust the reservoir levelfor booming soundFind the first and secondresonanting lengthsCalculate velocity ofsound

Key competencies

Calculate the focallength and powerof convex lensDraw u-v and 1/u -1/v graph

Find the time fornumber ofoscillationsFind the timeperiodCalculate theacceleration dueto gravityDraw l-T and l-T2

graph

Adjust thereservoir levelFind the first andsecond reso-nanting lengthsCalculate velocityof soundCalculate velocityof sound at 00 C


118

Find the least count ofvernier on microscopeFocus the microscope tothe lower meniscus &bent pinRead the scaleCalculate height of liquidriseCalculate the surfacetension of water

Find the least count ofvernierFix the capillary tube toaspiratory bottleFind the mass ofcollected water

Find the pressure headCalculate rate of volumeof liquid collectedFind the radius of capillarytubeCalculate the viscosity ofwater using capillarymethodDraw magnetic meridianPlaced the bar magnet inNN and NS directionsDraw magnetic lines offorceLocate the neutral pointsalong equatorial and axiallines

Read the scaleCalculate height ofliquid riseCalculate thesurface tension ofwater

Find the pressureheadCalculate rate ofvolume of liquidcollectedFind the radius ofcapillary tubeCalculate theviscosity of water

Draw magneticlines offorceLocate the neutralpointsalong equatorialandaxial lines

4. Surface tension ofliquid using trave-ling microscope(03)

5. Coefficient ofviscosity bycapillary method(03)

6. Mapping of magnetlines of force(03)

119

CHEMISTRY LAB PRACTICE - II(Common for all branches)

Subject Title : CHEMISTRY LABPRACTICE- II



Periods1. Determination of acidity of water sample 03

2. Determination of alkalinity of water sample 03

3. Determination of total hardness of waterusing Std. EDTA solution 03

4. Estimation of Chlorides present in watersample 03

5. Estimation of Dissolved Oxygen (D.O) inwater sample 03

6. Determination of pH using pH meter 03

Revision 03

Test 02

Total: 23


1.0 Conduct titrations adopting standard procedures to determinethe acidity of given samples of water (One ground water andone surface / tap water, and rain water if available)

2.0 Conduct titrations adopting standard procedures to determine

120

the alkalinity of given samples of water (One ground water andone surface / tap water)

3.0 Conduct titrations adopting standard procedures to determinethe total hardness of given samples of water (One ground waterand one surface / tap water) using Std. EDTA solution

4.0 Conduct titrations adopting standard procedures to determinethe chlorides present in the given samples of water andwastewater (One ground water and one surface / tap water)

5.0 Conduct the test using titrometric / electrometric method todetermine Dissolved Oxygen (D.O) in given water samples(One sample from closed container and one from opencontainer / tap water)

6.0 Conduct the test on given samples of water / solutions (likesoft drinks, sewage, etc.) to determine their pH using standardpH meter.


Periods)

Determination ofacidity of watersample (03)

Determination ofalkalinity of watersample (03)

Determination of totalhardness of waterusing Std. EDTAsolution (03)

Estimation ofChlorides present inwater sample (03)

Competencies

Cleaning the glasswareand rinsing withappropriate solutionsMaking standardsolutionsMeasuring accurately thestandard solutions andtitrantsFilling the burette withtitrantFixing the burette to thestandEffectively Controlling theflow of the titrantIdentifying the end pointMaking accurateobservationsCalculating the results

Key competencies

Making standardsolutionsM e a s u r i n gaccurately thestandard solutionsand titrantsE f f e c t i v e l yControlling the flowof the titrantIdentifying the endpointMaking accurateobservations


121

Estimation ofDissolved Oxygen(D.O) in water sample(By titration method)(03)

Estimation ofDissolved Oxygen(D.O) in water sample(By electrometricmethod) (03)

Determination of pHusing pH meter (03)

Familiarize withinstrumentChoose appropriate'Mode' / 'Unit'Prepare standardsolutions / buffers, etc.Standardize theinstrument withappropriate standardsolutionsPlot the standard curveFollow Safetyprecautions

Prepare standardsolutions / buffers,etc.Standardize theinstrument witha p p r o p r i a t estandard solutionsPlot the standardcurveMake measure-ments accurately

122

COMPUTER FUNDAMENTALS LAB PRACTICE-II (Common to All Braches other than CME & IT)

Subject Title : Computer FundamentalsLab Practice-II

Subject Code : MET-211Periods/Week : 03Periods/Semester : 45

LIST OF EXPERIMENTS1.0 MS-WORD1.1. Open MS-word and Identify the components on the screen

1.2. Create a document using MS-word and save it.

1.3. Create a table using MS-Word and save it.

1.4. Apply formulas in table & sort the table

1.5. Convert text into table & table into text.

1.6. Insertion of new rows and columns in the existing table andchanging background colour in table

1.7. Merge and split cells in a table

1.8. Change the font format

1.9. Exercise with Headers and Footers, paragraph tool bar.

1.10. Insert objects into the document like pictures, shapes, charts,word-art.

1.11. Create mailing letters using mail merge tool of MS-word

1.12. Exercise on printing a document , page setting, different viewsof a document

1.13. Import & export files to & from MS-Word.

2.0 MS-EXCEL2.1. Open MS-Excel and identify the components on the screen

2.2. Create a Worksheet in MS-Excel and save it in .xls or .xlsxformat

123

2.3. Insert a column and row in Excel

2.4. Exercise on creation of new worksheet in the existing ExcelBook file

2.5. Generate a Chart using the data in Excel-worksheet

2.6. Automate calculations in a worksheet using formulae

2.7. Sort and filter data in a worksheet

2.8. Protect a worksheet, working with multiple sheets

3.0 MS-POWERPOINT3.1. Create a simple Power point presentation for a small topic and

saving in .ppt or pptx format

3.2. Insert a new slide in the existing PowerPoint file

3.3. Insert chart or image in a PowerPoint slide

3.4. Exercise with animation and sound features in PowerPoint

3.5. Exercise with Rehearse Timings feature in PowerPoint

3.6. Exercise in printing the PowerPoint file in (a) Slides (b) Handouts

OBJECTIVES AND KEY COMPETENCIESS.No. Name of the

Experiments1. Open MS-Word

from (i) Programs(i i) Run andIdentify thecomponents onthe screen

2. Insertion of newrows andcolumns in theexisting table andchanging theb a c k g r o u n dcolour of the table

Objectives

Able to Open MS-wordand Identify thecomponents on thescreen

Able to Insert newrows and columns inthe existing tableAble to Change thebackground colour ofthe table

Key Competencies

Check whether able toIdentify the componentson the screenCheck whether able toIdentify all componentson the screen ofMSWORD are identifiedand learnt thoroughly

Check whether able toInsert new rows andcolumns in the existingtableCheck whether able toInsert new rows andcolumns as perrequirementCheck whether able toChange the backgroundcolour of the table

124

3. Merge and Splitcells in a Table

4. Change the fontformat

5. Exercise withHeaders andFooters

6. Create mail ingletters using mailmerge tool of MS-word

7. Open MS-Exceland identify thecomponents onthe screen

8. Create aWorksheet in MS-Excel and save itin .xls or .xlsxformat

9. Insert column androw in Excel

Able to Merge and splitcells in a Table usingright click method

Able to Change theformatting of font usingright click menuAble to Change theformatting of font usingmenu options

Able to changeHeaders and Footersusing menu optionAble to changeHeaders and Footersby clicking top andbottom document

Able to use mailmerge tool of MS-wordusing start mailmerge option in mailmenu

Able to Open MS-Exceland identify thecomponents on thescreen

Able to Create aWorksheet in MS-ExcelAble to save it in .xls or.xlsx format

Able to Insert columnand row in Excel usingmenu optionsAble to Insert columnand row in Excel byright clicking rows or

Check whether able toMerge and split cells ina Table using right clickmethod

Check whether able toChange the formatting offont using right cl ickmenuCheck whether able toChange the formatting offont using menu options

Check whether Able tochange Headers andFooters using menuoptionCheck whether able tochange Headers andFooters by clicking topand bottom document

Check whether Able touse mail merge tool ofMS-word in creating letterusing mail merge optionin mail menu

Check whether Able toOpen MS-Excel andidentify the componentson the screenCheck whether allcomponents are knownon screen

Check whether Able toCreate a Worksheet inMS-ExcelCheck whether Able tosave it in .xls or .xlsxformat

Check whether able toInsert column and row inExcel using menu optionCheck proper additionrows and columns ingiven sheet

125

10. Creation of newworksheet in theexisting ExcelBook file

11. Generate a Chartusing the data inExcel-worksheet

12. Automate calcula-tions in a work-sheet usingformula

13. Sort and filter datain a worksheet

columns appropriately

Able to createworksheet in theexisting Excel Book fileby using Insertworksheet optionbesides existingsheets

Able to Generate aChart using the data inExcel-worksheet

Able to Automatecalculations in aworksheet using fxformulaAble to use sigmafunctionAble to use functionlibrary option in formulamenu

Able to Sort data in aworksheet using sortoption in Data menuAble to Sort data in aworksheet using sortoption in right clickAble to filter data in aworksheet in datamenuAble to filter data in aworksheet in right click

Check whether able toInsert column and row inExcel by right clickingrows or columnsappropriately

Verify whether able tocreate worksheet in theexisting Excel Book fileby using Insertworksheet option

Check whether able toGenerate a Chart usingthe data in Excel-worksheetVerify whether chartprepared is as per thedata given

Check whether Able toAutomate calculations ina worksheet using fxformulaVerify whether Able touse sigma functionCheck whether Able touse function l ibraryoption in formula menu

Verify whether Able toSort data in a worksheetusing sort option in DatamenuVerify whether Able toSort data in a worksheetusing sort option in rightclickCheck whether Able tofilter data in a worksheetin data menuCheck whether Able tofilter data in a worksheetin right click

126

Able to Insert a newslide in the existingpowerpoint file usingnewslide option inhome menuAble to Insert a newslide in the existingpowerpoint file usingslide layout option inhome menu

Able to create a simplePower pointpresentation for a giventopicAble to Save thepresentation in both.ppt or pptx format

Able to Insert chart in apower point slide usingInsert menu optionAble to Insert image ina power point slideusing insert menuoption

Able to work withanimation and soundfeatures in power pointusing customanimation option inAnimations menuAble to work with Mediaclip options in insertmenu

Able to work withRehearse Timingsfeature in powerpointusing slide showmenu rehearse option

Able to print thepowerpoint file inSlides using File menuPrint optionAble to print thepowerpoint file inHandout using filemenu print option

Check whether Able toInsert a new slide in theexisting powerpoint fileusing newslide option inhome menuCheck whether Able toInsert a new slide in theexisting powerpoint fileusing slide layout optionin home menu

Check Able to create asimple Power pointpresentation for a giventopicCheck Able to Save thepresentation in both .pptor pptx format

Check Able to Insert chartin a power point slideCheck Able to Insertimage in a power pointslide

Check Able to work withanimation and soundfeatures in power pointusing custom animationoption in AnimationsmenuCheck Able to work withMedia clip options ininsert menu

Check able to work withrehearse timingsfeatures

Check to print thepowerpoint file in Slidesusing File menu PrintoptionCheck to print thepowerpoint file inHandout using file menuprint option

14. Insert a new slidein the existingpowerpoint file

15. Create a simplePower pointpresentation for asmall topic andsaving in .ppt orpptx format

16. Insert chart orimage in apowerpoint slide

17. Exercise withanimation andsound features inpowerpoint

18. Exercise withR e h e a r s eTimings feature inpowerpoint

19. Exercise inprinting thepowerpoint file in(a) Slides (b)Handout

127

II SEMESTER

128


III SEMESTER


/Week Semester


Hours Marks Marks

THEORY

MET-301 EngineeringMathematics-III 4 - 60 3 20 80 100

MET-302 Fuels Refractoriesand Pyrometry 5 - 75 3 20 80 100

MET-303 MetallurgicalThermodynamics 4 - 60 3 20 80 100

MET-304 Physical Metallurgy 5 - 75 3 20 80 100

MET-305 Iron Making 5 - 75 3 20 80 100

PRACTICALS

MET-306 Machine Drawing - 6 90 3 40 60 100

MET-307 Fuels Lab practice - 3 45 3 40 60 100

MET-308 Communicationskills and Life skillsLab Practice - 4 60 3 40 60 100

MET-309 MetallographyLab Practice-I - 3 45 3 40 60 100

MET-310 Mineral DressingLab practice - 3 45 3 40 60 100

TOTAL 23 19 630 300 700 1000

129

ENGINEERING MATHEMATICS - III(Common to all branches)

Subject title : Engineering Mathematics-IIISubject code : MET-301Periods per week : 04Total Periods per Semester: 60


S. Major Topic No of Weightage Short Type Essay Type No Periods of Marks

Unit - I R U App R U App

1. Indefinite Integration 18 32 2 2 0 1 1 0

Unit - II

2. Definite Integrationand its applications 17 31 0 1 1 1/2 1 1

Unit - III

3. NumericalIntegration 05 10 0 0 0 0 0 1

Unit - IV

4. DifferentialEquations of firstorder 20 37 2 2 0 1/2 1 1

Total 60 110 4 5 1 2 3 3

Marks: 12 15 3 20 30 30




130

ENGINEERING MATHEMATICS-IIICOMMON TO ALL BRANCHES


Unit-I1.0 Use Indefinite Integration to solve engineering problems1.1 Explain the concept of Indefinite integral as an anti-derivative.

1.2 State the indefinite integral of standard functions and propertiesof Integrals (u + v) dx and ku dx where k is constant and u,v are functions of x.

1.3 Solve integration problems involving standard functions usingthe above rules.

1.4 Evaluate integrals involving simple functions of the followingtype by the method of substitution.

i) f(ax + b) dx where f(x) dx is in standard form.

ii) [f(x)]n f (x) dx

iii) f (x)/[f(x)] dx

iv) f {g(x)} g (x) dx

1.5 Find the Integrals of tan x, cot x, sec x and cosec x using theabove.

1.6 Evaluate the integrals of the form Sinm Cosn . d where m andn are positive integers.

1.7 Evaluate integrals of powers of tan x and sec x.

1.8 Evaluate the Standard Integrals of the functions of the type

i) 2 2 2 2 2 2

1 1 1, ,a x a x x a

ii) 2 2 2 2 2 2

1 1 1, ,a x a x x a

131

iii) 2 2 2 2 2 2, ,x a x a a x

1.9 Evaluate the integrals of the type

1 da bSin

,

1cos

da b

and

1cos sin

da b c

1.10 Evaluate integrals using decomposition method.

1.11 Evaluate integrals using integration by parts with examples.

1.12 State the Bernoulli's rule for evaluating the integrals of the form

.u vdx .

1.13 Evaluate the integrals of the form ex [f(x) + f (x)] dx.

Unit-II2.0 Understand definite integral and use it in engineering

applications2.1 State the fundamental theorem of integral calculus

2.2 Explain the concept of definite integral.

2.3 Calculate the definite integral over an interval.

2.4 State various properties of definite integrals.

2.5 Evaluate simple problems on definite integrals using the aboveproperties.

2.6 Explain definite integral as a limit of sum by considering anarea.

2.7 Find the areas under plane curves and area enclosed betweentwo curves using integration.

2.8 Obtain the volumes of solids of revolution.

2.9 Obtain the mean value and root mean square value of thefunctions in any given interval.

Unit -III3.0 Understand Numerical Methods3.1 Explain the Trapezoidal rule, Simpson's 1/3 rules for

approximation of integrals and provide some examples.

132

Unit -IV4.0 Solve Differential Equations in engineering problems.4.1 Define a Differential equation, its order, degree

4.2 Form a differential equation by eliminating arbitrary constants.

4.3 Solve the first order first degree differential equations by thefollowing methods:

i. Variables Separable.

ii. Homogeneous Equations.

iii. Exact Differential Equations

iv. Linear differential equation of the form dy/dx + Py = Q,

where P and Q are functions of x or constants.

iv. Bernoulli's Equation (Reducible to linear form.)

4.4 Solve simple problems leading to engineering applications

COURSE CONTENTUnit-IIndefinite Integration:1. Integration regarded as anti-derivative - Indefinite integral ofstandard functions. Properties of indefinite integral. Integration bysubstitution or change of variable. Integrals of the form sinm. cosn.where m and n are positive integers. Integrals of tan x, cot x, sec x,cosec x and powers of tan x, sec x by substitution.

Evaluation of integrals which are reducible to the following forms

i) 2 2 2 2 2 2

1 1 1, ,a x a x x a

ii) 2 2 2 2 2 2

1 1 1, ,a x a x x a

iii) 2 2 2 2 2 2, ,x a x a a x

133

Integration by decomposition of the integrand into simplerational, lgebraic functions. Integration by parts , Bernoulli's rule.

Unit-IIDefinite Integral and its applications:2. Definite integral-fundamental theorem of integral calculus,properties of definite integrals, evaluation of simple definite integrals.Definite integral as the limit of a sum. Area under plane curves - Areaenclosed between two curves. Volumes of solids of revolution.Meanand RMS values of a function on a given interval.

Unit-IIINumerical Integration :3 Trapezoidal rule, Simpson's 1/3 rule to evaluate an approximatevalue of a definite integral.

Unit -IVDifferential Equations:4. Definition of a differential equation-order and degree of adifferential equation- formation of differential equations-solution ofdifferential equation of first order, first degree: variable-separable,homogeneous, exact, linear differential equation, Bernoulli's equation.

REFERENCE BOOKS:1. Integral Calculus Vol.I, by M.Pillai and Shanti Narayan

2. Thomas' Calculus, Pearson Addison -Wesley Publishers.

*****

134

FUELS, REFRACTORIES & PYROMETRYSubject Title : Fuels, Refractories & PyrometrySubject Code : MET-302Periods per week : 05Total periods per semester: 75


No Periods of Marks Answer AnswerType Type

(3 Marks) (10Marks)

1. Important industrialFuels 14 26 2 2

2. Gasification of fuels 10 13 1 1

3. Combustion of fuels 13 16 2 1

4. Refractories 10 13 1 1

5. Manufacturing ofRefractory bricks 12 23 1 2

6. Heat transfer 8 6 2

7. Pyrometry 8 13 1 1

Total 75 110 10 8

OBJECTIVESOn the completion of the course the student will be able tounderstand

1. Important Industrial Fuels1.1 Define the terms Fuel, Calorific value - Net and gross,

combustion of fuels, carbonisation, flash and fire points, Ignitiontemperature, coking .

1.2 Classify the fuels - based on occurrence and state.

1.3 State the origin of fuels.

1.4 State the various types of solid, liquid and gaseous fuels andtheir applications with chemical compositions.

1.5 Distinguish between proximate and ultimate analysis of coal.

135

1.6 Classify the coals - I S I and Seylors

1.7 Merits and Demerits of solid, liquid and gaseous fuels.

1.8 State the carbonisation processes - L.T and H.T.

1.9 Distinguish between Low temp and High temp carbonisation.

1.10 State the characteristics of metallurgical coke.

1.11 Explain the manufacturing processes of metallurgical coke bybeehive, retort and by product processes.

1.12 List out various by-products of coke oven & State their uses

1.13 Determine the flash point of the different fuel oils by usingPensky - Marten's apparatus.

1.14. Determine the fire point of the different fuel oils by usingCleveland apparatus

1.15 Determine the Kinematic & absolute viscosities of lubricatingoils to study the variation of the viscosity with temperature byusing Red Wood viscometer I & II.

1.16 Determine the Calorific Value of Solid & liquid fuels by usingBomb Calorimeter.

2. Gasification of solid fuels:2.1 Define gasification

2.2 State the purpose of gasification.

2.3 Explain the manufacturing processes of producer gas,

Water gas, carburetted water gas.

2.4 State the composition and uses of each gaseous fuel.

2.5 Distinguish between Producer gas and Water gas.

2.6 Distinguish between Water gas and Carburetted water gas.

2.7 State the composition and uses of B.F/c gas and Coke ovengas.

3. Numerical problems on combustion:3.1 Calculate the theoretical & actual air required for combustion.

3.2 Calculate the composition of products of combustion.

136

3.3 Convert the volume basis to weight basis and vice versa.

3.4 Calculate the calorific value of a fuel by Dulong's formula.

4. Refractories:4.1 Define the term refractory.

4.2 State the need of refractories.

4.3 Classify the refractory materials.

4.4 List out the properties of refractory materials.

4.5 Explain the properties of refractory materials.

4.6 Explain the tests on Refractories - Porosity, P.C.E., R.U.L. Bulkdensity, cold crushing strength, permeability.

4.7 Explain the causes of the refractory failures and their remedies.

5. Manufacture of refractory bricks:5.1 Explain the manufacturing of Alumino-Silicate Refractories -

Fire clay.

5.2 State the properties and applications of Fire clay Refractories.

5.3 Explain the manufacturing process of SiO2 refractory.

5.4 State the properties and applications of Silica Refractories.

5.5 Explain the manufacturing process of magnesite refractories

5.6 State the properties and applications of magnesite Refractories.

5.7 Name the neutral Refractories.

5.8 Describe the manufacturing process of Carbon Bricks.

5.9 State the properties and applications of Carbon bricks.

6. Heat transfer by conduction & radiation:6.1 state different modes of heat transfer.

6.2 Define conduction and thermal conductivity.

6.3 State the Fourier's law of heat conduction.

6.4 Calculate the rate of Heat transfer in single and composite wallof metallurgical Systems.

6.5 Define radiation.

137

6.6 State the Stefan - boltzman law of radiation and its equation.

6.7 Define black body, Emissivity, Absorbivity, reflectivity.

6.8 State Planck and Wien's law of distribution of radiant energy.

7. Pyrometry:7.1 Define pyrometer.

7.2 State the need of Pyrometers.

7.3 State different types of pyrometers.

7.4 Explain the working principle of thermocouple.

7.5 State the advantages,limitations and applications.

7.6 State the Principle of resistance pyrometers.

7.7 State the advantages,limitations and applications.

7.8 Describe the working principle of Optical pyrometers.

7.9 Explain the working of Radiation pyrometers.

7.10 Compare Optical and Radiation Pyrometers.

COURSE CONTENTS1.0 Important Industrial Fuels:

Definition of Fuel, calorific value (Net & Gross) combustion,Ignition temperature, flash & fire points, carbonisation, coking.

Classification of fuels: - primary fuels, Secondary fuels,

Solid fuels: - Analysis of coal, Classification of coals, Liquid

Fuels, Gaseous fuels, comparative study, carbonisation -L.T,

H.T, characteristics, Beehive, Retort, by-product oven.

Determination of flash & fire point, viscosity, calorific value ofrespective oils/solid fuels

2.0 Gasification of solid fuels:Definition, purpose, manufacture of producer gas, water gas,carbonated water gas, composition and their uses, By-productgaseous fuels - B.F. gas, C.O gas, composition and uses.

138

3.0 Numerical problems on combustion:Calculation of theoretical air & Actual air,

Calculation of composition of production of combustion.

Conversions of volumetric basis to weight basis & vice verse.

Calculation of calorific value of fuel by Dulong's formula.

4.0 Refractories:Definition, purpose, classification, properties, testing ofproperties, causes of refractory failures and their remedies.

5.0 Manufacture of refractory bricks:Manufacturing of fire clay, silica, magnesite, and carbon brickswith flow sheets. Properties and uses.

6.0 Heat transfer by conduction & radiation:Concept, modes, definition of conduction, conductivity, Fourier'sLaw, calculation of rate of heat transfer in single wall compositewall of metallurgical system, radiation, Stefan- Boltzaman Law,Black body, Emissivity, Absorbsity, Reflectivity, Plank's andWien's laws.

7.0 Pyrometry:Definition, necessity, types of pyrometers, resistancepyrometer, thermocouples, optical pyrometer, radiationpyrometer.

TEXT BOOK1. Fuels, Furnaces and Refractories - by O.P. Gupta

REFERENCE BOOKS1. Refractories - by Chasti.

2. Metallography laboratory practice -by G.L.Kehl.

3. Fuels and combustion -by Sameer sarkar.

*****

139

METALLURGICAL THERMODYNAMICSSubject Title : Metallurgical ThermodynamicsSubject Code : MET-303Periods per week : 04Total periods per semester: 60



(3 Marks) (10 Marks)

1. Introduction andapplication ofthermodynamics 06 13 1 1

2. First law ofthermodynamics 10 13 1 1

3. Thermo-chemistry 08 16 2 1

4. Second law ofthermodynamics 10 23 1 2

5. Ellingham diagrams 04 06 2 -

6. Phase Equilibria 07 13 1 1

7. Fugacity, Activity andEquilibrium constant, 08 13 1 1

8. Solutions 07 13 1 1

Total 60 110 10 08


1.0 Introduction and applications of thermodynamics1.1 Applications of Thermodynamics

1.2 Define ideal gas and derive the ideal gas equation PV=nRT.

1.3 Define system, surrounding & boundary with examples.

1.4 Distinguish between Homogeneous and Heterogeneoussystems.

140

1.5 Define isolated system, closed system, open system andadiabatic system.

1.6 Define intensive, extensive properties, state and path propertieswith examples.

1.7 Define state of a system and equation of state.

1.8 Define equilibrium state and the criteria for equilibrium.

1.9 Explain isothermal, adiabatic, Isochoric and Isobaric process.

1.10 Define reversible and irreversible processes and statedifferences between them.

1.11 Explain the terms heat and work with units. (S.I. Units) statesign conventions of heat and work.

1.12 Explain about pressure - volume work (or) work of expansion.Derive equation for work of expansion.

1.13 State complete / exact differential of thermodynamic properties.

2.0 First law of Thermodynamics2.1 State First law of thermodynamics.

2.2 Explain energy content and energy changes.

2.3 Derive heat changes at constant volume and constantpressure.

2.4 Explain concept of enthalpy or heat content.

2.5 Define heat capacity.

2.6 Define heat capacities at constant volume and constantpressure.

2.7 Derive the relation between heat capacities at constant volumeand constant pressure.

2.8 State heat capacity - temperature relationships.

2.9 Define reversible adiabatic expansion and compression.

2.10 Derive the fallowing relations in reversible adiabatic process.

a) Temperature - Volume relationship

b) Pressure - Volume relationship

c) Temperature - Pressure relationship

141

2.11 Solve a range of problems using the above derivations andequations from the above mentioned objectives.

3.0 Thermo Chemistry3.1 Define heat of reaction.

3.2 Define heat of reaction at constant pressure and constantvolume.

3.3 Define exothermic and endothermic reactions and the signconventions of H from E.

3.4 Define heat of formation

3.5 Define heat of combustion.

3.6 State the thermo-chemical laws

a) Laplace Law.

b) Hess law of constant heat summation.

3.7 Explain variation of heat of reaction with temperature and derivethe Kirchhoff's equation.

3.8 Solve a range of problems using the above derivations andEquations from the above mentioned objectives.

4.0 Second law of Thermodynamics.4.1 State the Second law of thermodynamics.

4.2 Define spontaneous and irreversible process.

4.3 Derive the efficiency of Carnot engine.

4.4 State the concept of entropy and the relation.

4.5 State the entropy changes in reversible and irreversibleprocesses

4.6 Define entropy change and phase change.

4.7 State the conditions for equilibrium in terms of change in Entropy

4.8 Derive equation for variation of entropy with temperature.

4.9 State third law of thermodynamics.

4.10 State the concept of free energy.

4.11 Derive the free energy relationships.

142

4.12 State the conditions for equilibrium in terms of change in freeenergy.

4.13 Derive the Gibbs - Helmholtz Equation.

4.14 Define partial molar properties.

4.15 Define chemical potential - partial molar free energy.

4.16 Solve a range of problems using derivations and equations fromthe above-mentioned objectives.

5.0 Ellingham diagrams5.1 Understand the construction of the standard free energy -

temperature ( Go - T) diagram.

5.2 Explain Go - T diagram in terms of the formation of FeO,Fe2O3, Fe3O4, CO2& CO.

5.3 State the applications of Go - T diagram.

5.4 State the limitations of Go - T diagrams.

6.0 Phase Equilibria6.1 Explain the equilibrium between phases of one component

system.

6.2 Derive the CLAPEYRON equation.

6.3 State the equation for solid-liquid equilibrium, liquid-vapourEquilibrium and solid- Vapor equilibrium.

6.4 Derive the CLASIUS CLAPEYRON equation and explain itsapplications.

6.5 State the vapor pressure-temperature relationships.

6.6 State Trouton's rule.

6.7 Solve a range of problems using derivations and equations fromthe above mentioned objectives.

7.0 Fugacity, Activity & Equilibrium Constant7.1 Define fugacity, activity and equilibrium constant.

7.2 State the equation for fugacity of an ideal gas & Non Ideal gas

7.3 Define chemical equilibrium.

143

7.4 State Le-chatliers rule for law of mass of action.

7.5 Explain the factors effecting the position of equilibrium.

7.6 Define equilibrium constant.

7.7 Derive the VANTHOFF's equation for isotherm and Isochors.

7.8 Solve range of problems using derivations and equations inthe above mentioned objectives.

8.0 Solutions8.1 Define Solution, Mole Fraction, Weight % and Atom %.

8.2 Know the conversion of Weight % to Atom % and Atom % toWeight %.

8.3 Classify Solutions; Define Ideal Solution & Regular Solution.

8.4 State Roults law for ideal solutions.

8.5 Define the activity coefficient.

8.6 State the factors causing deviation from ideal behavior.

8.7 Define dilute solution and state Henry's law.

8.8 State Sieverts law and its applications.

8.9 Solve range of problems using derivations and equations inthe above mentioned objectives.

COURSE CONTENS1.0 INTRODUCTION TO THERMODYNAMICS:

Applications, Ideal gas equation, system & types, properties ofsystem, equilibrium state, thermodynamic processes, work ofexpansion.

2.0 FIRST LAW OF THERMODYNAMICS:Introduction, Heat change, Heat capacity, relation between Cp& Cv, enthalpy, Heat capacity & temperature relationship.

3.0 THERMOCHEMISTRYHeat of relation, Heat of formation, heat of combustion,endothermic & exothermic reactions, thermo chemical laws,solve a range of problems.

144

4.0 SECOND LAW OF THERMODYNAMICSIntroduction, Carnot cycle, Entropy changes, free energy,Gibbs- helmoboltz equation, chemical potential , partial molarproperties, solve a range of problems.

5.0 ELLINGHAM DIAGRAMSConstruction of Ellingham diagram for the formation of FeO,Fe2O3, Fe3O4, CO2 and CO uses and limitations

6.0 PHASE EQUILIBRIAClasius - Clapeyron equation, equation for solid- liquid, liquid-vapour& solid-vapour equilibrium, Troutons rule, solve a rangeproblems.

7.0 FUGACITY, ACTIVITY & EQUILIBRIUM CONSTANTIntroduction to fugacity of an ideal & non-ideal gas, position ofequilibrium, Vanthoff equation solve a range of problems.

8.0 SOLUTIONSDefinitions, classification, Raoult's law & ideal solution, Henry'slaw &dilute solution, Sieverts law, regular solution, solve a rangeof problems

TEXT BOOKS1. Metallurgical thermodynamics- by Gaskel

2. Thermodynamics for chemists- by S. Glasstone

REFERENCE BOOKS1. Problems in metallurgical Thermodynamics and kinetics- by

Dube RK and Upadhyaya GS

2. Chemical metallurgy- by J.J. More.

3. Physical chemistry of Metals- by Darken & Gurry.

4. Introduction to Metallurgical Thermodynamics Tupkary RH

5. Text book of Materials and Metallurgical Thermodynamics byAhindra Ghosh.

******

145

PHYSICAL METALLURGYSubject Title : Physical MetallurgySubject Code : MET-304Periods per week : 05Total periods per semester: 75




1. Structure of Metals andAlloys 11 13 1 1

2 Solidification of Metalsand Alloys. 12 21 2 1

3 Binary ThermalEquilibrium Diagrams 15 26 2 2

4 Study of Iron - CarbonSystem 12 16 2 1

5 Study of important Non-Ferrous binary Systems 13 18 1 2

6 Microscopic and Macro-scopic examination ofMetals and Alloys 12 16 2 1

Total 75 110 10 08

OBJECTIVESUpon the completion of study of the subject the student shouldbe able to Understand

1.0 Structure of Metals and alloys.1.1 Explain Metallic bond.1.2 Define Space lattice & Unit Cell.1.3 State different Crystal Systems and classify them into Space

Lattices.1.4 Define the terms:

a) Lattice parameter,

146

b) Co-ordination number,c) Effective no. of atoms per unit cell (N)d) Atomic radius,e) Inter planer spacing.

1.5 Calculate the c/a ratio for H.C.P. Structure.1.6 Calculate the Atomic packing factor for

a) BCC b) FCC c) HCP1.7 Know Miller & Miller Bravias Indices.1.8 Find out the Miller & Miller Bravias indices for Different Planes

and Directions.1.9 Calculate the Planar Density for different planes.2.0 Solidification of Metals & Alloys2.1 Differentiate Metal & Alloy.2.2 Define Phase & List the types of Solid phases.2.3 Define Solid solution and classify the Solid Solutions.2.4 Explain the rules governing the formation of Solid Solutions.2.5 State different types of Intermediate phases and their properties.2.6 Define cooling curve.2.7 Draw the cooling curves for a pure metal and alloy.2.8 Explain the process of crystallization with respect to

a) Nucleationb) Growthc) Under cooling

2.9 Define dendritic growth & Coring2.10 Define Homogeneous Nucleation.2.11 Define Heterogeneous Nucleation.3.0 Binary thermal Equilibrium Diagrams.3.1 Define Equilibrium diagram.3.2 State the applications and limitations of Equilibrium diagrams.3.3 Classify the Binary Systems.3.4 Define an Isomorphous system.

147

3.5 Explain the Construction of Equilibrium diagram for anIsomorphous System.

3.6 Definea) Liquidus lineb) Solidus linec) Tie line

3.7 State Lever Rule and its applications.3.8 State the phase rule and explain the terms

a) Phase.b) Number of components.c) Degrees of freedom

3.9 State the applications of phase rule in Binary phase diagrams.3.10 Explain the Cooling of an alloy in Isomorphism System by

showing the microstructures at various points duringSolidification.

3.11 Calculate the amount of phases at various temperatures inIsomorphous System using Lever Rule.

3.12 Define an Eutectic reaction.3.13 Draw the equilibrium diagrams of Eutectic systems with

examples.3.14 Explain the cooling of eutectic, hypoeutectic and hypereutectic

alloys showing the microstructures at various points duringSolidification.

3.15 Calculate the amount of phases at various temperatures inEutectic systems using Lever Rule

3.16 State property variations in Eutectic system.3.17 Define Peritectic reaction.3.18 Draw the equilibrium diagram of a peritectic system with

examples.3.19 Define eutectoid reaction.3.20 Define peritectoid reaction3.21 Define monotectic reaction3.22 Define Syntectic reaction

148

4.0 Study of Iron - Carbon System4.1 Define Allotropy and list the examples4.2 State the allotropic transformation in pure iron and curie

temperature,4.3 State the importance and characteristics of iron - Carbon

system.4.4 Draw the Phase Diagram of Iron - Iron Carbide System.4.5 Define a) Austenite b) Ferrite c) Cementite d) Ledeburite e)

Pearlite4.6 Define steel and cast iron.4.7 State the differences between cast iron and steel.4.8 Explain the Isothermal transformations in Iron-Iron Carbide

System.a) Peritectic b) Eutectic c) Eutectoid

4.9 DefineEutectoid, Hypo & Hyper eutectoid steels.4.10 Explain the phase transformations during slow cooling for

Eutectoid, Hypo & Hyper eutectoid steels with the help ofmicrostructures.

4.11 Calculate the amount of phases at various temperatures usingLever Rule.

4.12 State the upper & lower critical temperatures.4.13 State the effect of carbon on mechanical properties of steel.4.14 Classify cast irons and draw their microstructures.5.0 Study of Important Non-ferrous binary systems.5.1 Draw the Copper-Zinc equilibrium diagram up to 50% Zinc.5.2 Explain the peritectic reaction in Copper-Zinc system.5.3 List out the different types of brasses.5.4 State the composition, properties and applications of alpha

brasses.5.5 Explain season cracking and its remedies.5.6 State the composition, properties and applications of alpha+

beta brasses.5.7 Draw the typical microstructures of alpha and alpha+ beta

brasses.

149

5.8 State the composition of high tensile brass5.9 Draw the equilibrium diagram for Copper-Tin System.5.10 Explain the peritectic reactions in Copper-Tin System.5.11 State the composition, properties and applications of

a) Phosphor Bronze b) Gun metal c) Aluminum bronze.5.12 State the composition, properties and applications of Copper

Nickel alloys5.13 Draw equilibrium diagram for Aluminum-Silicon System.5.14 Explain the cast structure of Aluminum-Silicon eutectic.5.15 Explain the modification treatment and modified structure of

Aluminum-Silicon eutectic.5.16 Draw Lead-Tin equilibrium diagram.5.17 Draw Lead-Antimony equilibrium diagram.5.18 State the composition, properties and applications of Babbitts5.19 Draw the typical microstructure of Babbitts.6.0 Microscopic and Macroscopic Examination of Metals.6.1 List the various parts of a microscope.6.2 Explain the principle & operation of a metallurgical microscope

with the help of line diagram.6.3 State the various types of objective lenses.6.4 State the various types of microscope eyepieces.6.5 State the working principle of Scanning & Transmission

Electron microscope.6.6 Compare Optical & Electron Microscope.6.7 Define Macroscopic Examination & Microscopic Examination.6.8 State the importance of macroscopic examination.6.9 State the importance of Microscopic examination.6.10 Explain the Steps involved in the preparation of specimen for

Microscopic examination.a) Mounting b) Polishing c) Etching.

6.11 Explain the etching mechanism.6.12 List the etchants for important ferrous and Non-ferrous metals

and alloys.

150

COURSE CONTENTS1.0 Crystal Structure: Define Metallic Bond, Space lattice, Unit

cell, classify crystal systems into space lattices, , Latticeparameter, Co-ordination Number, Effective Number of atoms,Calculate "c/a" ratio for HCP, packing factor of BCC, FCC, HCPStructures, know Miller & Miller Bravias Indices, Find out theMiller & Miller Bravias indices for Different Planes and Directions.Calculate the Planar Density for different planes.

2.0 Solidification of Metals and Alloys: Differentiate Metal & Alloy,types of Solid phases, Cooling curves, process of crystallizationwith respect to Nucleation, Grain growth & under cooling,Dendritic Growth & Coring, Homogeneous & HeterogeneousNucleation,

3.0 Binary thermal Equilibrium Diagrams: Phase rule and DefineEquilibrium diagram, usefulness of Equilibrium diagrams,Classification of Binary Systems, Understand Equilibriumdiagrams of different Alloy Systems, Solidus line, Liquidus line,Tie line Rule & Lever Rule, Application of Phase rule to Binaryphase diagram.

4.0 Study of Iron-Carbon diagram: Allotropy Transformations inpure Iron, curie temperature, meta-stable phase, iron - Carbonsystem, Isothermal Transformations Iron - Carbon System,Hypo & Hyper eutectoid steels, transformations during slowcooling - for different steels, upper & lower critical temperatures,effect of Carbon on Mechanical properties of steel,Classification of Cast irons.

5.0 Study of Important Non-ferrous binary systems: Copper-Zinc equilibrium diagram up to 50% Zinc, different brasses,season cracking and its remedies, Copper, Nickel alloys withcomposition and applications, equilibrium diagram of Copper-Tin System, Aluminum-Silicon equilibrium diagram, modifiedstructure of Aluminum-Silicon eutectic, Lead-tin equilibriumdiagram, Lead-Antimony equilibrium diagram, Babbitt metal.

6.0 Microscopic and Macroscopic Examination of Metals:Parts of a microscope, principle & operation of a metallurgical

151

microscope, objective lenses and eye pieces, their usefulness,Working principle of Scanning & Transmission Electronmicroscope, Macroscopic Examination & MicroscopicExamination, Steps involved in the preparation of specimen forMicroscopic examination, etching mechanism, types ofetchants.

REFERENCE BOOKS1. Introduction to physical metallurgy - Sydney H. Avener2. Physical metallurgy - V.Raghavan3. Physical metallurgy for engineers - Clark&Warney4. Physical metallurgy - Lakhtin5. Metallurgy for engineers - Rollason6. Materials science and Metallurgy - kodigere.

*****

152

IRON MAKINGSubject Title : Iron MakingSubject Code : MET-305Periods per week : 05Total periods per semester : 75




1 Iron ores and theirpreparation 15 16 2 1

2 Burden distribution 8 13 1 1

3 Blast furnace profile& reactions 10 13 1 1

4 Blast furnace plant &equipment 10 13 1 1

5 Blast furnace operation 16 26 2 2

6 Alternate Methods ofpig iron production 8 13 1 1

7 Recent developmentsin Iron making 8 16 2 1

Total 75 110 10 08

OBJECTIVESOn the completion of the course the student will be able tounderstand:

1.0 Introduction of iron making1.1 List various types of iron ores.

1.2 Give the chemical composition, specific gravity of various ores

1.3 Classify the iron ores based on colour and gangue materialassociated

1.4 State the importance of evaluation of ores

1.5 Explain the factors in the evaluation of ores

153

1.6 Mention reserves of iron ores in India

1.7 State the need of preparation of iron ores for charging into blastfurnace

1.8 State the different Methods of preparation of iron ores

1.9 Define the term agglomeration

1.10 State purpose of agglomeration

1.11 Identify the different Methods of agglomeration

1.12 Define the term sintering

1.13 State the principle of sintering

1.14 Identify the factors affecting sintering

1.15 Explain the construction and operation of Dwight Lloyd sinteringmachine

1.16 Know various types of sinters.

1.17 Define the term pelletizing

1.18 State the principle of pelletizing

1.19 Explain the process of palletising-disc and drum pelletizing

1.20 Appreciate the advantages and disadvantages of pellets oversinter

2.0 Burden Distribution2.1 Define the term blast furnace burden.

2.2 Explain the charging methods of raw materials in blast furnace.

2.3 State the importance of burden distribution.

2.4 State the methods of distributing the burden inside the furnace

2.5 Explain the factors effecting burden distribution.

3.0 Blast furnace profile and reactions3.1 Explain the profile of Blast furnace

i) Throat ii) Stack iii) Bosh iv) Hearth

3.2 Know the lining details of blast furnace

3.3 Understand the term useful volume of Blast Furnace

154

3.4 State the raw materials required

3.5 State the purpose of adding Coke and Limestone.

3.6 Explain the reactions in various zones of blast furnace withreference to the descending column of raw materials andascending column of gases.

3.7 Define direct & indirect reduction.

3.8 Define coke rate & importance of Co/Co2 ratio

3.9 List the main product and other by - products of blast furnace

3.10 Identify the constituents of ascending gases and state its use.

4.0 Blast furnace plant and equipment4.1 Draw the layout of blast furnace plant.

4.2 List the sections in Blast furnace plant.

4.3 Know the methods of raw material storage and its supply tothe blast furnace.

4.4 Explain the construction and operation of Hot Blast Stove.

4.5 State the principle of Dust Catcher, Scrubber and ElectrostaticPrecipitator.

4.6 Explain the operation of Dust Catcher, Scrubber andElectrostatic Precipitator.

5.0 Operation of blast furnace5.1 Explain the method of starting the B/F operation

5.2 State the procedure of banking the furnace

5.3 Mention the procedure for blowing out operation

5.4 State the composition of pig iron

5.5 State the favorable conditions for the removal of Silicon,Manganese, Sulphur and Phosphrous

5.6 Explain the external desulphurisation by soda ash treatment.

5.7 Explain the ladle desiliconisation process.

5.8 Identify the Methods of disposing pig iron by Pig casting machineand hot metal ladles

155

5.9 State the function of blast furnace slag5.10 Know the constituents of blast furnace slag and slag basicity.5.11 State the by product value of slag5.12 State the Methods of disposing the slag5.13 List out the irregularities in blast furnace operation5.14 Discuss the causes and remedies for each irregularity6.0 Alternative Methods of iron production6.1 State the necessity of other Methods of pig iron production6.2 List out the other Methods of pig iron production6.3 Define the terms - Sponge Iron, Percentage of reduction and

degree of metallisation6.4 Classify Sponge Iron making processes.6.5 Explain the physical chemistry of DRI processes6.6 Explain the production of DRI by Coal based processes i.e

rotary Kiln process6.7 Explain the production of DRI by Gas based processes i.e

Midrex Process.6.8 State the applications of DRI7.0 Recent developments in iron making:7.1 know the recent reduction smelting processes - Corex, Elred,

Inred, Plasma smelting.7.2 Explain the reduction smelting of iron ores in Corex process.7.3 Explain Plasma smelting.7.4 list out recent trends of blast furnace7.5 Explain

a) Large capacity furnacesb) High top pressure operationc) Burden preparation& burden distributiond) Oxygen Enrichmente) Humidification of blastf) Fuel Injection through tuyeres

156

COURSE CONTENTS1.0 IRON ORES AND THEIR PREPARATION: Types, chemical

composition, classification, Evaluation, Deposits in India, Needof preparation, Methods of preparation Agglomeration Methods,Sintering, Dwight Lloyd sintering machine, Types of sinters,Pelletisation, Disc and Drum pelletisers, Comparison of sinterand pellets.

2.0 BURDEN DISTRIBUTION: Raw materials, Double Bellcharging, Principles of Burden distribution, factors effectingBurden Distribution

3.0 BLAST FURNACE PROFILE AND REACTIONS: Profile ofBlast furnace, Construction and lining details, useful volume,constituents of Ascending gases, Reactions in various zones,Direct and Indirect reduction, co/co2 ratio

4.0 BLAST FURNACE PLANT AND EQUIPMENT: Lay out, Rawmaterial storage and supply, Hot Blast stoves, Dust catcher,scrubber, Electro static precipitator.

5.0 OPERATION OF BLAST FURNACE: Blowing-in, Banking,Blowing-out, Disposal of pig Iron,: Function of slag, Fusibility,Constitution, By product value, de sulphurisation Pig castingmachine, Irregularities.

6.0 ALLTERNATIVE METHODS OF PIG IRON PRODUCTION:Necessity, Types of Alternative methods, Sponge Iron: Rotarykiln process and Midrex process, corex process

7.0 RECENT DEVELOMENT IN IRON MAKING: Recentreduction smelting processes, Corex process, PlasmaSmelting process. Large capacity Blast Furnace, Burdenpreparation, High Top Pressure operation, Oxygen enrichment,Humidification of Blast.

REFERENCE BOOKS1. Iron & Steel Vol -1 by Bashforth2. Iron making by R.H.Tupkary3. Elements of metallurgy by D. Swaroop4. Beyond Blast Furnace By AmitChatterjee5. Smelting reduction of iron ores by Chatterjee6. Sponge iron production in rotary kiln by Sarangi&sarangi7. Principles of blast furnace iron making by A.K. Biswas

*****

157

MACHINE DRAWINGSubject Title : Machine DrawingSubject Code : MET-306Periods / Week : 06Periods / semester : 90



1 Introduction 06 - - -

2 Fastening Devices 21 10 02 -

3 Assembly Drawings 42 80 - 02

4 Piping Layouts andJoints 12 05 01 -

5 Welding FabricationDrawings 09 05 01 -

Total: 90 100 04 02

Note: Candidate has to answer all questions in part- A and onequestion out of two in part- B

OBJECTIVESUp on completion of the course the student shall be able to

1.0 Understand the importance of machine drawing1.1. Explain the importance of Machine drawing.

1.2. Review of 1st angle and 3rd angle Projections

1.3. Review of Orthographic Projections and Sectional Views.

2.0 Practice the drawing of fastening devices2.1. Draw the standard thread profiles.

2.2. Draw bolted connections to standard proportions.

2.3. Draw different types of screws.

2.4. Draw different types of rivets and riveted connections.

158

2.5. Draw different types of keys and cotters.

3.0 Understand the assembly drawing practice and procedure3.1. List the sequence of steps for preparing assembly drawing.

3.2. Practice the assembly drawing for the given componentsdrawing.

3.3. Prepare the list of parts.

4.0 Practice the construction piping layouts4.1. State the distinction between pipes and tubes.

4.2. Identify the common components of a piping layout.

4.3. Identify the conventional symbols used for the variouscomponents of piping layout.

4.4. Prepare single line and double line diagrams of piping layouts.

4.5. Draw the assembly drawing and sectioned views of pipe joint.

4.6. Explain the use of packing material in joint.

5.0 Appreciate the welded fabrication drawing.5.1. Identify the different types of welds and their symbolic

representation as per B.I.S., SP-46-1988.

5.2. Identify the elements of welding symbol and their standardlocation on the symbol.

5.3. State welding process to be used, surface contour and finishof weld when given in symbolic form.

5.4. Practice the Preparation of working drawing of weldedfabrications.

Key competencies to be achieved by the studentTopic Key competencyIntroduction Understand the difference

between I & III angle projections

Appraise the importance ofsectional views in MechanicalEngineering

Fastening devices Differentiate the temporary and

159

permanent joints and theirapplications

Draw the bolts, screws, nuts,rivets, keys and cotters withstandard proportions

Assembly drawing Read the external and internalfeatures of each part

Prepare the table of parts givingpart number, its name, materialand quantity

Piping layouts Acquaint with the symbols usedfor the various components ofpiping layout

Understand the importance anduse of all the valves and packingmaterial used in pipe fittings

Welded fabrication drawing Specify the weld joint

Prepare the working drawing ofwelded fabrications.

COURSE CONTENT1.0 Introduction1.1. Importance of Machine Drawing.

1.2. Brief revision of 1st and 3rd angle projections

1.3. Understand the concepts of Orthographic projections andSectional views.

2.0 Fastening Devices2.1. Temporary and Permanent fastenings and their areas of

application-thread nomenclature, forms of screw threadprofiles, metric, B.A., Acme, Knuckle, etc.

2.2. Bolts and Nuts: Specification of bolts and nuts, Different typesof bolted joints (like using through bolts, studs, screws etc.,) indifferent applications. Purpose of lock nuts and their Types.

160

2.3. Keys and cotters: Types of keys and cotters: Differencebetween key and cotter uses.

2.4. Rivets and Riveted joints: Types and proportions andspecification of rivets: Different types of riveted joints: Lap, butt-single row, double row etc., chain and zigzag riveting -calculation of diameter of rivet: Pitch and arrangement of rivetsin row - use - of standard proportions.

Drawing Plate: 11. Exercise on Orthographic projections and Sectional views.

2. Thread Nomenclature and forms of screw thread profiles.

3. Exercises in drawing - bolted connections using standardproportions.

4. Drawing of various types of lock nuts & types of keys indicatingtheir proportionate dimensions.

5. Exercise in drawing riveted joints using standard proportions:Single row, double row (chain and zigzag) in lap and butt joints(single & double strap).

3.0 Assembly Drawings3.1. Need and functions of assembly and detailed drawings.

3.2. Steps in preparing assembly drawings.

3.3. Bill of materials and parts list.

3.4. Exercises in preparing assembly drawings of commonlyavailable engineering components.

Drawing Plate: 2Draw the views / sectional views of1. Jib and cotter joint assembly

2. Knuckle joint assembly

3. Assembly of muffs coupling (sold & split) coupling

4. Screw jack assembly,

5. Stuffing box.

6. Bearings.

161

NOTE: With the knowledge gained by the above exercises thestudents shall be able to draw exercises on Socket and spigotjoint, protective type flanged coupling, piston of petrol engine,cross head, connecting rod, eccentric, flexible coupling,universal coupling, sleeve and cotter joint, Oldham's-coupling,lathe tool post, big end of a connecting rod, foot step bearing,Plummer block, lathe tail stock.

4.0 Piping layouts4.1. Classification of pipes and tubes.

4.2. Components of pipes lay-out.

4.3. Screw fitting bend, elbow, tee, lateral Cross-nipple, reducingsocket and plug.

4.4. Unions: Screwed ground and flanged.

4.5. Valves: Gate valve: angle valve, check valve.

4.6. Various conventional symbol used for the above components.

Drawing Plate: 31. Single line diagram of pipe layout two exercises.

2. Double line diagram of pipe layout one exercise.

3. Cast iron flanged pipe joint, spigot and socket joint, hydraulicpipe joint, expansion joint, screwed joint, union joint - draw halfsectional elevation and end view.

5.0 Welded fabrication drawings5.1. Different types of weld and their basic symbols including

sectional representation as per table of I.S. standards, fillet,square butt, single V-Butt, double V-Butt, single bevel butt,double bevel butt, stud, bead (edge or seal) spot, seam.

5.2. Elements of welding symbol and their standard location thesymbol as per IS standards reference Kode arrow head, weldsymbol supplementary symbol dimensions of welds, methodof welding process, special reference.

5.3. Significance of arrow & position of arrow head significance ofreference line as per I.S. standards with reference to fillet, V-Butt an stud welds.

162

5.4. Supplementary symbols and special instructions: surface ofreference line; as per I.S. standards with reference to fillet, V-Butt an stud welds.

5.5. Dimensions of welds: length, location and spacing of welds asper I.S., B.I.S., standards with showing dimensions requiredon a welding.

5.6. Need of special reference

Drawing Plate: 41. Drawing tables and figs. Referred in the contents above taking

form I.S. standards.

2. Dimensioning a given welding drawings as per I.S., SP-46-1988.

3. Preparing working drawing of welding fabrication from givendata.

REFERENCE BOOKS1. T.S.M & S.S.M in respect of Technical Drawing by TTTI, Madras

2. Machine Drawing by A.C. Parkinson.

3. Machine Drawing by Jones & Jones.

4. Machine Drawing by N.D. Bhat.

5. A text book for Technical Schools Engg. Drawing by N.C.E.R.T

6. Machine Drawing by R.B. Gupta.

7. Indian Standard Scheme of symbol for Welding by SP-46-1988.

8. Machine Drawing by Bhattacharyya (Oxford Publishers).

9. Machine Drawing by Ajeeth Singh (MGH Publishers)

10. Machine Drawing by N.Siddeswar, Kannaih, Sastri. (MGHPublishers).

*****

163

FUELS LAB PRACTICESubject Title : Fuels Lab PracticeSubject Code : MET-307Periods per week : 03Total periods per semester: 45

TIME SCHEDULE

Sl.No. Experiment Title No. of periods1 Proximate analysis 12

2 Flash point &Fire point 12

3 Viscosity 11

4 Calorific value 10

Total periods 45

OBJECTIVESUp on Completion of the course the student shall be able to:

1.0 To estimate the amount of moisture, volatile matter , ashand fixed carbon of given sample of coal

1.1 Define proximate analysis

1.2 Types of moisture contents in coal

1.3 Working of oven

1.4 Handling of apparatus

1.5 Observing and manipulating of furnace temperature

1.6 Use empirical formulae to determine moisture, volatile matter,ash and fixed carbon of given sample of coal

1.7 Explain the need and scope of the Experiment in industry

2.0 Understand the determination of flash and fire point of agiven sample of fuel using given apparatus

2.1 Define the flash and fire points of fuels.

2.2 Distinguish between "open" and "close" tests.

164

2.3 Identify the Parts of apparatus

2.4 Explain the function of each component part

2.5 Handle the apparatus

2.6 Manipulate the apparatus

2.7 Perform the precise operations to determine flash

and fire point of given sample of fuel

2.8 Record the observations

2.9 List the Precautions and safety procedures

2.10 Explain the need and scope of the Experiment in industry.

3.0 Understand the determination of Viscosity of a givensample of oil using given apparatus

3.1 Explain the properties of lubricating oil

3.2 Explain the viscosity of oil and its units

3.3 Explain the importance of viscosity as applied to Oils.

3.4 Relate the Absolute viscosity and kinematic viscosity

3.5 Classify the viscometers

3.6 Identify the parts of viscometer



3.9 Perform the precise operations to record Redwood seconds

3.10 Use empirical formulae to determine the Kinematic & Absoluteviscosities of given Oil.

4.0 Understand the determination of Calorific value of a givensample of fuel using given apparatus

4.1 Explain the phenomenon of combustion of fuel

4.2 Explain the calorific value of fuel

4.3 State the differences between higher and lower Calorific Valuesof fuels.

4.4 List the types of fuels

4.5 Indentify the parts of Junker's Gas Calorimeter

165


4.7 Perform precise operations on bomb, Junker's Calorimeter torecord various parameters

4.8 Determine the Calorific values of solid, liquid and gaseous fuels

Key competencies to be achieved by the student

Title of the experiment Key competency

1. Proximate analysis 1. Weigh the porcelain cruciblewith and without coal sample.

2. Place the bowl in oven andfurnace

3. Opening and closing of furnace

2. Flash and Fire point tests 1. Observe the flame for changein color and type of flame

2. Record the temperature of fuelusing thermometer

3. Viscosity measurement 1.Handle the Hydrometer tomeasure the density of given oil

2. Record the temperature of oilusing thermometer

3. Record the time to collect 50ml of oil

4. Calorific value tests 1. Weigh the water collected andcondensed steam

2. Record the inlet &outlettemperature of water

3. Record volume of gas burnt

166

COURSE CONTENT1. Estimate the amount of moisture, volatile matter,ash&fixed

carbon of given coal sample

2. Determination of flash and fire points of various fuels andlubricants using Pensky Martin's, and Cleveland's apparatus.

3. Determination of Kinematics and Absolute viscosities of thefuel and lubricating Oils using Redwood &Say bolt viscometers.

4. Determination of Calorific values of Solid and liquid fuels usingBomb Calorimeter

5. Determination of Calorific value of gaseous fuel by usingJunker's Calorimeter.

*****

167

COMMUNICATION SKILLS AND LIFE SKILLS LABPRACTICE

(Common to all the branches)Subject Title : Communication Skills and Life

Skills Lab PracticeSubject Code : MET-308Periods per week : 04Total periods per semester: 60

TIME SCHEDULES. Major Topics No. of Weightage No. of

No Periods of Marks Questions

I Communications Skills

1. Listening (Unit-1 & 2) 10 10 1

2. Speaking (Unit- 3 to 6) 10 10 1

3. Group Discussion (Unit-7) 5 10 1

4. Interview Skills (Unit-8) 5 10 1

II Life Skills

5 Unit-1 to 4 15 30 1

6 Unit-5 to 8 15 30 1

Total 60 100 6

168

Communication Skills Sl. No

Unit Objectives Key Competencies

1 Listening- I

Listen for the main idea Listen for specific details

Learn to listen for main idea Listen for specific details Listen and understand varied

material Make inferences Know appropriate vocabulary

2 Listening-II

Listen for and identify the main idea

Listen for and identify specific details

Learn to listen for main idea Listen for specific details Listen and understand varied

material Make inferences Know appropriate vocabulary

3 Introducing |Oneself

Introduce oneself Learn vocabulary

relevant to making introductions

Learn the difference between an informal and formal introduction

Use formal and informal introduction appropriately

Know relevant vocabulary to talk about skills, hobbies, strengths and weaknesses

4 Describing Objects

Learn vocabulary and expressions useful for describing objects

Describe objects

Learn to describe an object Use relevant vocabulary

5 Reporting Past Incidents

Report past incidents Use appropriate grammar

and vocabulary for reporting

Use appropriate tense Learn appropriate vocabulary Know how to express past

incidents 6 Just A

Minute Speaking fluently and

accurately for a minute Learn to speak on any given

topic Sequencing ideas organizing

thoughts Know how to introduce a given

topic Learn how to give a good

closure Know and avoid common

mistakes 7 Group

Discussion

Understand the concept of a group discussion

Participate in a group discussion

Learn the do’s and don’ts of group discussion

Participate in a group discussion

Learn appropriate vocabulary and expressions

Use good body language Know group dynamics Be aware of do’s and don’ts in a

group discussion Know appropriate etiquette

8 Interview Skills

Prepare for an interview Face an interview

Get the confidence to face an interview

Learn good body language Know frequently asked

questions and answer them appropriately

Learn to dress properly for an interview

Know the do’s and don’ts

169

Life Skills

Sl. No

Unit Objectives Key Competencies

1 Positive Attitude

Concept of positive attitude

Learn to think positively Become confident

2 Goal Setting Importance of setting goals

Learn to set goals Know how to achieve goals Know about personal and

professional goals 3 Time

Management To manage time in an efficient manner

Know about time wasters Learn to plan, prioritize,

schedule Learn to become productive Learn to manage time

productively 4 Problem

Solving and Decision Making

Learn to solve problems and take appropriate decisions

Learn the steps in problem solving

To think out of the box Learn to solve the problems

rationally 5 Creativity To become creative Think innovatively

Learn to think out of the box Learn to look at old things in

a new way Think differently

6 Managing Emotions

Understand different emotions

Learn to manage stress Know about anger

management Understand and manage

emotions 7 Teamwork Importance of

teamwork Learn to be a team player Know the importance of

teamwork Learn the traits of a good

team Know the stages in a team

formation 8 Leadership

Skills Concept of leadership

Learn leadership traits Know leadership styles Be a future leader

Total Marks: 100

Internal: 40 marks

External: 60 marks

170

End Examination:Listening skill: 10 marks

Speaking Skill: 10 marks

(Describing Objects, Reporting past incidents, JAM)

Interview Skills or Group Discussion: 10 marks

Life Skills: 30 marks

Internal Assessment:Attendance, Discipline: 5 marks

Lab manual Submission: 15 marks

Classroom presentations: 20 marks

*****

171

METALLOGRAPHY LAB PRACTICE-ISubject Title : Metallography lab Practice-ISubject Code : MET-309Periods per week : 03Periods per semester : 45

TIME SCHEDULES.No. Major Topic No. of Periods1 Metallurgical Microscope 9

2 Preparation of Specimen 6

3 Preparation of Etching Reagents 6

4 Microstructures of Steels 12

5 Microstructures of Cast Irons 12

TOTAL 45


1.0 Operating a metallurgical microscope1.1 To know the parts of metallurgical microscope1.2 Able to know coarser adjustment and finer adjustment1.3 Handling of apparatus1.4 Placing of prepared specimen under the objective lens1.5 Eye pieces of different magnifications1.6 Resolving power in metallurgical microscope1.7 Differences between micro and macro examination1.8 Studying of Microscope Image Analyser2.0 Preparation of specimen for metallographic examination2.1 To know the rough grinding equipment2.2 Parts of rough grinding equipment2.3 Grades of emery papers for intermediate polishing2.4 To know the way of polishing specimen on emery paper

172

2.5 Mixing of alumina powder with water for fine polishing2.6 Parts of fine polishing machine3.0 Preparation of Etching Reagents for Ferrous and Non

Ferrous Metals3.1 Identify the etching reagents used for Ferrous and Non Ferrous

Metals3.2 To know the composition of chemicals for preparation of etching

reagents3.3 Effect of etching reagent on polished specimen3.4 Difference between under etching and over etching3.5 To know about the etching techniques4.0 Microstructures of Steels 4.1 Identify the phases in the Low Carbon Steels 4.2 Identify the phases present in Medium Carbon Steels4.3 Identify the phases present in High Carbon Steels4.4 Identify the phases present in Eutectoid Steels5.0 Microstructures of Cast Irons5.1 Observation of Cast irons in unetched condition.5.2 Identify the phases present in White Cast Iron5.3 Identify the phases present in MalleableCast Iron5.4 Identify the phases present in in Grey Cast Iron5.5 Identify the phases present in Spheroidal Graphite Cast Iron.

*****

173

Title of the ExperimentMetallurgical microscope

Preparation of sample

Etching reagents

Microstructures of Steels

Microstructures of Cast Irons

KEY Competencies to be achieved by the studentKey competency

1. Adjustment of corner and finerknobs

2. Placing the sample on mountingtable

3. Observing the micro structure

1. Selection of proper sample2. Selecting the order of different

grades of Emery papers forpolishing

3. Way of polishing on Emerypaper

4. Fine polishing on disc polisher

1. Selecting reagents for ferrousmetals

2. Selecting reagents for NonFerrous metals

3. Applying the Etching Reagent onprepared specimen surface

4. Etching techniques and etchingtime

1. Identifying the phases inmicrostructures of different typesof Steels

1. identifying the grain boundriesand inclusions in unetchedcondition. Identifying the phasesin microstructuresof differentCast Irons

COURSE CONTENT1. Studying and operating a Metallurgical Microscope.2. Preparation of a Specimen for Metallographic Examination.3. Preparation of Etching Reagents for Ferrous Metals.4. Observation and Studying Microstructures of different steels.5. Observation and Studying Microstructures of stainless steels,

case hardened steels and weld steel.*****

174

MINERAL DRESSING LAB PRACTICECourse Title : Mineral Dressing Lab

PracticeCourse Code : MET-310Periods per week : 03Periods per semester : 45

TIME SCHEDULES. No. Major Topics No. of Periods1 Jaw crusher 6

2 Roll Crusher 6

3 Ball Mill 6

4 Rod Mill 3

5 Rotap sieve shaker 6

6 Vibrating Screens 6

7 Mineral Jig 6

8 Floatation cell 6

TOTAL 45

OBJECTIVESUp on the completion of the course the student shall be ableto:

1. Determine the energy consumption as a function of sizereduction by using Jaw crusher and verify theenergyconsumption & size reduction relationship with Crushinglaws - Kicks law and Rittinger's law

2. Determine the energy consumption as a function of sizereduction by using Roll crusher.

a) Verify the energyconsumption & size reduction relationshipwith Crushing laws - Kicks law and Rittinger's law

175

b) Determination of Energy consumption as a function of sizereduction by using Roll crusher and calculate the angle of NIPof Roll crusher.

3. Study the effect of the following variables on grinding in a BallMill

a) Determination of energy consumption as a function of sizereduction

b) Variation of energy consumption as a function of time ofreduction.

4. Study the effect of following variables on grinding in a Rod Mill.



5. Perform the Sieve analysis of the given material by using RotapSieve shaker and Plot the fallowing graphs

a) Size in microns vs. percentage Wt. Retained by individualsieve By using ASTM/BSS sieves.

b) Size in micros vs. Cumulative weight percentage coarse &finer

6. Determination of effectiveness of screening in separating thegiven material by use of vibrating screens

7. Concentrate the given Mineral by using the mineral Jig

a) Through the screen

b) Above the screen.

8. Study the flotation characteristics of a sulphide ore using a FrothFlotation cell.

*****

176

KEY Competencies to be achieved by the studentExperiment Title

Jaw crusher

Roll crusher

Ball mill

Key Competencies

1. Construction of Jaw crusher2. Reduction ratio3. Equation for power

consumed4. How to read the energy

meter readings5. Kick's law and Ritterger's

law6. Calculation of average size

of feed and product7. Industrial applications of Jaw

crusher

1. Construction of Roll crusher2. Reduction ratio3. Equation for power


meter readings5. Kick's law and Ritterger's

law6. Calculation of average size

of feed and product7. Measurement of

circumference of roll therebyits diameter

8. Equation for angle of NIP9. Industrial applications of Roll

crusher

1. Construction of Ball mill2. Reduction ratio3. Equation for power


meter readings

177

5. Critical speed of the mill6. Calculation of average size

of feed and product7. Open circuit grinding and

closed circuit grinding8. Industrial applications of ball

mill

1. Construction of Ball mill2. Reduction ratio3. Equation for power

consumed4. How to read the energy meter

readings5. Critical speed of the mill6. Calculation of average size

of feed and product7. Open circuit grinding and

closed circuit grinding8. Industrial applications of Rod

mill

1. Know BSS, ASTM andclassification of sieves

2. Relation between aperturesize and sieve number

3. Need of measuring averagesize of the particles

4. Equation foe determiningaverage size of the particle

5. Working mechanism ofRotap sieve shaker

6. Interpretation of graphbetween size in microns vs.percentage Wt. Retained byindividual sieve by usingASTM/BSS sieves.

7. Size in micros vs. cumulativeweight percentage coarse &finer

Rod mill

Rotap sieve shaker

178

8. Industrial applications ofsieve analysis

1. Know BSS, ASTM andclassification of sieves

2. Relation between aperturesize and sieve number

3. Need of separation ofparticles

4. Effect of blind particle on theeffectiveness of screen

5. Mechanism of vibratingscreen

6. Calculation of weightfractions on each sieve

7. Industrial applications ofVibrating screens

1. Mineral, Ore and concentrate2. Interpretation of Stokes law3. Renaults number4. Free settling and hindered

settling5. Terminal velocity and settling

velocity of the particles6. Settling of small dense

particle and coarse lightparticles

7. Suction and pulsation8. Industrial applications of

Mineral jig

1. Purpose of agitation of bath2. Hydrophobic particles and

aero phobic particles3. Purpose and names of

frother, collector, activatorand depressors

4. Industrial applications ofFroth flotation

Vibrating screens

Mineral Jig

Flotation cell

179

COURSE CONTENTS1. Determination of the energy consumption as a function of size

reduction by using Jaw crusher and verification of the energyconsumption & size reduction relationship with Crushing laws- Kicks law and Rittinger's law

2. Determination of energy consumption as a function of sizereduction by using roll crusher verify the energyconsumption& size reduction relationship with Crushing laws - Kicks lawand Rittinger's law - Calculation of angle of NIP

3. Study the effect of the following variables on grinding in a BallMill



4. Study the effect of the following variables on grinding in a Rodmill



5. Perform the Sieve analysis of the given material by using Rotapsieve shaker and Plot the necessary graphs

6. Determination of effectiveness of screening in separating thegiven material by using differentVibrating screens

7. Concentrating the given Mineral by using the mineral Jig

8. Study the flotation characteristics of a sulphide ore using a FrothFlotation cell.

*****

180

IV SEMESTER

181


IV SEMESTER


/Week Semester


Hours Marks Marks

THEORY

MET-401 EngineeringMathematics-IV 4 - 60 3 20 80 100

MET-402 ElectricalTechnology 4 - 60 3 20 80 100

MET-403 Material Testing 4 - 60 3 20 80 100

MET-404 Foundry Technology 5 - 75 3 20 80 100

MET-405 Heat TreatmentTechnology 5 - 75 3 20 80 100

MET-406 Steel Making 4 - 60 3 20 80 100

PRACTICALS

MET-407 Material TestingLab Practice-I - 3 45 3 40 60 100

MET-408 Heat TreatmentLab Practice - 6 90 3 40 60 100

MET-409 Foundry LabPractice - 3 45 3 40 60 100

MET-410 Programming inC Lab Practice - 4 60 3 40 60 100

TOTAL 26 16 630 280 720 1100

182

ENGINEERING MATHEMATICS - IV(Common to all branches)

Subject title : Engineering Mathematics-IVSubject code : MET-401Periods per week : 04Total Periods per Semester: 60

TIME SCHEDULE with BLUE PRINT

S. Major Topic No of Weightage Short Essay No Periods of Marks Questions Questions

R U A R U A

Unit -I

1. Homogenous LinearDifferential equationswith constant coefficients 05 09 1 2 0 0 0 0

Unit - II

2. Non-homogenousLinear Differentialequations withconstant coefficients 15 26 1 1 0 1 1 0

Unit - III

3. Laplace Transforms 25 49 2 1 0 2 1 1

Unit - IV

4. Fourier Series 15 26 1 1 0 1/2 1/2 1

Total 60 110 5 5 0 3 2 2 1/2 1/2

Marks 15 15 0 35 25 20

R: Remembering type 50 marks

U: Understanding type 40 marks

App: Application type 20 marks

183

ENGINEERING MATHEMATICS- IVCOMMON TO ALL BRNACHES


Unit-IDifferential Equations1.0 Solve Homogeneous linear differential equations with

constant coefficients in engineering situations1.1 Solve Differential equations of the type (aD2 +bD + c)y = 0

when the roots of the auxiliary equation are real and different,real and repeated, complex.

1.2 Solve the higher order homogeneous differential equations withconstant coefficients.

Unit-II2.0 Solve Non Homogeneous linear differential equations

with constant coefficients in engineering situations2.1 Explain the concept of complementary function, particular

Integral and general solution of a differential equation.

2.2 Solve nth order differential equation of the type f(D) y = X wheref(D) is a polynomial of nth order and X is a function of the formk, eax , Sinax, Cosax, xn.

Unit-III3.0 Use Laplace transforms to solve differential equation in

engineering problems3.1 Write the definition of Laplace Transform and Laplace transform

of standard functions.

3.2 Explain the sufficient conditions of existence of LaplaceTransform.

3.3 Write the properties of Laplace Transform - Linear property,First shifting property, Change of Scale.

3.4 Solve simple problems using the above properties

184

3.5 Write formulae for Laplace transform of ( )nt f t , ( )f tt ,

( ) ( )nf t , 0

( )t

f u du interms of Laplace transform of ( )f t .

3.6 Solve simple problems using the above formulae.

3.7 Define unit step function and write the Laplace Transform ofunit step function.

3.8 Write second shifting property.

3.9 Define inverse Laplace Transform and write inverse LaplaceTransform of standard functions.

3.10 Solve simple problems on 3.9

3.11 Write first shifting property of inverse Laplace Transfrom.

3.12 Solve simple problems on 3.11

3.13 Write inverse Laplace Transforms corresponding to LaplaceTransform of the functions mentioned in section 3.5

3.14 Solve simple problems on 3.13.

3.15 Define convolution of two functions and state convolutiontheorem.

3.16 Solve simple problems on 3.15.

3.17 Use Laplace and inverse Laplace Transforms to solve simpledifferential equations of second order.

Unit-IV4.0 Understand the Fourier series expansion of functions4.1 Define the orthogonality of functions in an interval.

4.2 Define Fourier series of a function on the interval ( , 2 )c c

and write the Euler's formulae for determining the Fouriercoefficients.

4.3 Write sufficient conditions for the existence of Fourier seriesfor a function.

185

4.4 Find Fourier series of simple functions in the range (0, 2 )and ( , ) .

4.5 Write Fourier series for even and odd functions in the interval( , ) .

COURSE CONTENTDifferential Equations1. Homogenous linear differential equations with constant

coefficients of order two and higher with emphasis on secondorder.

2. Non-homogenous linear differential equations with constantcoefficients of the form f(D)y = X, where X is in the form k, eax,sin ax, cosax, xn, (n= 1,2) - complimentary function, particularintegral and general solution.

Laplace Transforms (LT)3. Definition, sufficient conditions for existence of LT, LT of

elementary functions, linearity property, scale change property,first shifting property, multiplication by tn, division by t, LT ofderivatives and integrals, unit step function, LT of unit stepfunction, second shifting theorem, inverse Laplace transforms-shifting theorems and change of scale property, multiplicationby sn and division by s - examples of inverse LT using partialfractions - convolution theorem (no proof) - applications of LTto solve ordinary differential equations with initial conditions (2ndorder only)

Fourier series4. Orthogonality of trigonometric functions, Representation of a

function in Fourier series over the interval , 2c c , Euler'sformulae, sufficient conditions for existence of Fourier seriesfor a function, even, odd functions and their Fourier series over

the interval 0, 2 .

REFERENCE BOOKSHigher Engineering Mathematics, B.V.Ramana, Tata McGraw-Hill.

*****

186

ELECTRICAL TECHNOLOGYSubject Title : Electrical TechnologySubject Code : MET-402Periods per week : 04Total periods per semester: 60




1. D.C. circuits & Measu-ring instruments 08 13 1 1

2. Electro Magnetism andElectromagneticInduction 08 13 1 1

3. D.C. Generators 07 13 1 1

4. D.C. Motors 07 13 1 1

5. A.C. Circuits 08 16 2 1

6. Transformers 06 13 1 1

7. A.C. Machines 08 13 1 1

8. RenewableEnergy Sources 08 16 2 1

Total 60 110 10 08

OBJECTIVESUpon the completion of studying this subject, the student shouldbe able to:

1.0 Solve D.C. Series - parallel circuits and know the use ofmeasuring instruments

1.1 Calculate equivalent resistance of series - parallel circuits

1.2 To solve problems on series - parallel circuits

1.3 State and explain Kirchhoff's laws

1.4 State the use of M.C. and M.I. Ammeter and Voltmeter.

187

1.5 State the use of Megger, Multi meter and Energy meter inelectrical measurements.

2.0 Understand principles of Electro-Magnetism andElectromagnetic Induction

2.1 Explain the terms - Permeability, Field strength, Flux and FluxDensity.

2.2 State cork screw rule

2.3 Express field strength due to a straight current carryingconductor (No derivation)

2.4 Express Field strength on the axis of a solenoid (No derivation)

2.5 State Faraday's Laws of Electro - Magnetic Induction

2.6 State Lenz's Law

2.7 Explain self induced e.m.f and mutually induced e.m.f

2.8 State expression for self-inductance and mutual inductance(No derivation).

3.0 Understand working of D.C. Generators3.1 Explain working principle of D.C. generators

3.2 List the parts of D.C. generators and materials used

3.3 State functions of each part of D.C. generator.

3.4 State E.M.F equation

3.5 Solve formula substitution problems on E.M. F. equation.

3.6 Classify D.C. Generators and indicate current directions.

4.0 Understand working of D.C. Motors4.1 Explain principle of working of D.C. motors

4.2 Classify D.C. motors and indicate current directions.

4.3 State back E.M.F. (no derivation)

4.4 Write formula for speed of D.C. motor in terms of supply voltagecurrent and flux.

4.5 State Torque equation (no derivation).

4.6 Explain necessity of starter.

188

4.7 Explain the working of 3-point starter.

4.8 Explain speed control of D.C. shunt motor by Armature controland Field control

4.9 State applications of D.C. motors

5.0 Understand Single and Three phase systems5.1 Define: waveform, cycle, time, period, frequency, instantaneous

value, maximum value, average value and R.M.S. value.

5.2 State expression for average and R.M.S. values in terms ofmaximum value.

5.3 Explain instantaneous value in terms of maximum value.

5.4 Explain phase and phase difference (with graph only), andpower factor.

5.5 State equation for power in single-phase circuits.

5.6 State actual, apparent and reactive currents and powers.

5.7 State phase and line voltage & currents and their relationshipsin star and delta connections.

5.8 State the expression for power in a 3-phase circuit.

5.9 Work problems on star and delta connected loads.

6.0 Know working of Single and 3 phase Transformers6.1 Explain working principle of transformers.

6.2 Explain construction of a transformer.

6.3 Classify transformers based on types of core

6.4 State step up and step down transformers.

6.5 State autotransformer and its uses.

6.6 Comprehend the construction and working of 3 phasetransformers

6.7 Explain Scott - connection method

7.0 Explain the working of Induction Motors and Alternators7.1 Describe the constructional details of an induction motor.

7.2 Explain the principle of operation of induction motors.

189

7.3 Define Torque and Slip in Induction motors.

7.4 Explain the methods of starting of induction motors.

7.5 Classify the Three Phase and Single Phase induction motors.

7.6 State the applications of induction motors.

7.7 Describe the constructional details of an alternator.

7.8 Explain the principle of operation of alternator

8.0 Study Renewable energy sources and comprehend Solar& Wind power

8.1 Define Non-Conventional Energy sources.

8.2 State the necessity of Non conventional Energy sources.

8.3 List out the non-conventional energy sources and classify them.

8.4 Appreciate the applications of various non-conventional energysources in India.

8.5 Explain the use of solar energy as non-conventional source.

8.6 Explain the principle of solar energy converter.

8.7 Explain the construction of a solar panel.

8.8 Mention the important specifications of solar panels.

8.9 Describe solar energy conversion system with a block diagram.

8.10 List out the merits and demerits of solar energy converters

8.11 Applications of solar energy

8.12 Fundamentals of wind energy

8.13 List out the different types of wind mills

8.14 Explain the working principle of a wind mill

COURSE CONTENTS1. Solutions of D.C. series, parallel circuits, and Kirchoff's laws -

Electrical Instruments, ammeter, voltmeter, Megger, multi meterand energy meter (single phase).

2. Electro Magnetism, electromagnetic induction, self and Mutualinductances

190

3. D.C. generators, working construction, types of generatorsE.M.F. equation

4. D.C. motors- working, types of motors, applications, backE.M.F, torque equation, 3point starter, speed control

5. Single phase circuits, generation of E.M.F. wave form valuesof A.C., phase and phase difference, power factor, equation forpower, different expressions for apparent and reactive power.Generation of 3 phases E.M. F., star and delta connectedsystem and loads.

6. Transformers single phase and 3-phase transformers autotransformer- conversion of 3 phases to 2 phases.

7. Induction motors and Alternators : Induction Motors,Classification - constructional details Principles of operation -Torque, slip - Starters, Types of Three phase & Single phasemotors- Applications with respect to Metallurgical Industry-Constructional details of alternators and Principle of OperationAlternator..

8. Non-Conventional Energy sources - necessity of Nonconventional Energy sources. Classification and applicationsof non-conventional energy sources in India - Solar energy asnon-conventional source - Principle of solar energy converter -Construction of solar panels and their specifications - solarenergy conversion system - Merits and Demerits of solarenergy converters - Applications of solar energy - Fundamentalsof wind energy - Types of windmills - Working principle of awindmill.

REFERENCE BOOKS1. Electrical Technology by B.L. Theraja

2. Advanced Electrical Technology by H. Cotton

3. Electrical Technology by Huges

4. Electrical technology by V.K. Mehta.

5. Electrical Engineering by M.S.Naidu& S.Kamakshiah

6. Non-conventional energy guidelines by NEDCAP

7 Solar energy utilisation by G.D.

*****

191

MATERIAL TESTINGSubject Title : Material TestingSubject Code : MET-403Periods per week : 04Total periods per semester: 60




1. Tension test 10 26 2 2

2. Hardness test 10 16 2 1

3. Fracture 6 13 1 1

4. Impact test 6 13 1 1

5. Fatigue test 8 13 1 1

6. Creep test 6 13 1 1

7. Non - Destructive testing 14 16 2 1

Total 60 110 10 08

OBJECTIVESOn completion of this subject the student should be able toUnderstand

1 TENSION TEST1.1 Know importance of tension test in industrial application.

1.2 Define stress & strain

1.3 Plot the Engineering stress - strain curve from the data.

1.4 Explain the salient features of the stress - strain curve.

1.5 Identify the specifications of test samples for tension test

1.6 Define the important tensile properties viz., UTS, YS. Proofstress, percentage elongation, percentage reduction in area,resilience and toughness

1.7 Calculate the above properties from the test data.

192

1.8 Numerical problems on tensile data1.9 Draw the stress - strain curve for ductile and brittle materials.1.10 Define true stress, true strain.1.11 Convert the engineering strain to true strain1.12 Convert engineering stress to true stress1.13 Know Flow curve and its mathematical equation.1.14 Define the importance of flow curve properties viz., true stress

at maximum load, true uniform strain, true local necking strain,true fracture stress

1.15 Explain the necking phenomenon.1.16 Derive the two conditions for necking viz., the true stress is

equal to the slope of the flow curve and true strain equals tothe strain hardening coefficient

1.17 Define modulus of elasticity, modulus of rigidity, Bulk modulus,Poisson's ratio.

1.18 Know the relation between the above four.1.19 Discuss the effect of temperature on tensile properties.2. Hardness test2.1 Know the importance of hardness test.2.2 Define hardness & Classify hardness tests.2.3 State the scratch hardness & Name different minerals in Moh's

scale of hardness2.4 Know the principle of Brinell hardness test.2.5 Know different Indentors and loads used for different materials.2.6 Know the test procedure of Brinell Hardness Test.2.7 Understand the terms 'Ridging' "and "'Sinking in'".2.8 Measure the indentation diameter with the help of Brinell

Microscope.2.9 Derive BHN formula.2.10 Calculate the hardness number using BHN formula.2.11 Find the industrial importance of Brinell hardness test.2.12 Know the principle of Vickers's hardness test.

193

2.13 Know the Indentors and loads used.2.14 Know the test procedure of VHN test.2.15 Measure the diagonal length of impression with the help of

microscope.2.16 Calculate the hardness number from the test data.2.17 Find the industrial importance of Vickers's hardness test.2.18 Know the principle of Rockwell hardness test.2.19 Know different combinations of Indentors and loads used.2.20 Explain the description of the dial.2.21 Read the hardness value from the dial.2.22 Convert the Rockwell to Brinell hardness number.2.23 Know the principle of Rockwell superficial hardness test.2.24 Know the importance of Rockwell superficial hardness test.2.25 Know the different Indentors and the loads used in Rockwell

superficial hardness test.2.26 Know Micro hardness test, find the applications of Tukon

hardness test.2.27 Calculate the Knoop hardness number from the test data.2.28 Discuss the importance of Rebound hardness test.2.29 State the industrial applications of Shore scleroscope.3. Fracture3.1 Know what fracture is3.2 Differentiate the ductile and brittle fracture.3.3 Derive the equation for theoretical cohesive strength.3.4 Explain the Griffith theory of brittle fracture.

3.5 Analyse different metallographic aspects of fracture.4. Impact test4.1 Identify the specifications of test samples for conducting Izod

and charpy tests.4.2 Explain the principle of operation of Izod and charpy impact

tests.4.3 Define notch sensitivity.

194

4.4 Define notch toughness

4.5 Define Ductile Brittle Transition Temperature (DBTT).

4.6 Know the factors which effect transition temperature (I.e.DBTT).

5. Fatigue test5.1 Know the importance of the fatigue test.

5.2 Explain the different cycles of stress Alternating, Repeating &fluctuating.

5.3 Explain loading systems reverse bend, torsion and tension-compression.

5.4 Plot the S-N curve from the test data and identify the endurancelimit

5.5 Discuss typical fatigue failure.

5.6 Explain the theories of fatigue Orowan's and Wood's concept.

5.7 Explain the effect of stress concentration on fatigue.

5.8 Explain the effect on surface roughness on fatigue.

5.9 Explain the effect of surface residual stress on fatigue.

5.10 Explain the effect of corrosion on fatigue properties.

5.11 Explain the effect of metallurgical variables on fatigue properties.

5.12 Explain the effect of temperature on fatigue properties.

5.13 Identify the specifications of test samples for fatigue test.

6. Creep test6.1 Define creep.

6.2 Know the importance of creep test.

6.3 Know the essential features of creep test.

6.4 Explain the creep curve and its regions.

6.5 Know the presentation of creep data.

6.6 Explain the mechanism of creep.

6.7 Know the stress - rupture test.

6.8 Distinguish stress - rupture test and creep test.

195

7. Non-destructive testing7.1 Explain the need of non- destructive test.

7.2 Know the importance of Non- destructive test.

7.3 Explain Visual examination.

7.4 State the steps involved in dye penetrant test.

7.5 State the principle of magnetic particle test.

7.6 Know about longitudinal magnetization

7.7 Know about circular magnetization

7.8 Explain the Magnetic Particle test

7.9 Know the de-magnetisation methods

7.10 State the principle of radiography

7.11 Know the interpretation of radiograph.

7.12 Give the precautions while carrying out radiography.

7.13 State the importance of ultrasonic test.

7.14 State the principle of ultrasonic test.

7.15 Know the calibration of ultrasonic test.

7.16 Explain the test procedure for ultrasonic test.

7.17 Know the interpretation of ultrasonic test result.

7.18 State the importance of Eddy current test.

7.19 State the principle of Eddy current test.

7.20 Know the applications of Eddy current test.

COURSE CONTENTS1.0 Tension test - Introduction. Stress strain diagram and its salient

features. Tensile properties, effect of temperature, true stressstrain diagram. Various features, necking phenomena, Elasticconstants

2.0 Hardness test - Definition of hardness, classification, varioushardness tests Brinell, Rockwell, Vicker's, Micro hardness test,and Shore scleroscope - principles, operation and applications.

196

Relevant derivations

3.0 Fracture - Definition, ductile and brittle fracture, cohesivestrength equation, Grif f ith theory of brittle fracture,metallographic aspects of fracture

4.0 Impact test - Test specimens, principles of operation of testingmachines, Notch sensitivity, Notch toughness, transitiontemperature.

5.0 Fatigue test - Importance, different cycles, S-N Curve,endurance limit, Fatigue failures, theory of fatigue, effect ofsurface, metallurgical variables and temperature on fatigue,test sample specifications.

6.0 Creep test - Definition, importance, salient features of creepcurve and mechanism of creep, stress - rupture test.

7.0 Non Destructive testing - Need for non destructive testing,various non destructive tests, - Visual, Dye penetrant, Magneticparticle, Radiography, Ultrasonic and Eddy current test.

TEXT BOOKS1. The testing of metallic Materials - by A.V.K. Suryanarayana

REFERENCE BOOKS1. Mechanical metallurgy by G.E. Dieter

2. Non-destructive testing by Barry Hull and Vernon John, ELBS.

3. Principles of metallographic Laboratory Practice by Kehl

4. Practical Non - Destructive Testing by Baldevraj, JayakumarT, Thavasimuthu M.

*****

197

OBJECTIVESOn completion of the subject the student should be able tounderstand

1.0 Introduction1.1 Define the terms foundry, casting, pattern.

1.2 Classify the foundries.

1.3 State the advantages and limitation of foundry as a productionprocess.

1.4 List the basic steps involved in a casting process such as

FOUNDRY TECHNOLOGYSubject Title : Foundry TechnologySubject Code : MET-404Periods per week : 05Total periods per semester: 75




1. Introduction 4 3 1 -

2. Patterns 10 13 1 1

3. Moulding Sands 12 13 1 2

4. Cores 4 6 2 -

5. Moulding process 15 23 1 2

6. Hand moulding tools and equipment 6 3 1 -

7. Machine mouldingEquipment 8 13 1 1

8 Pouring and feedingof casting 10 13 1 1

9 Defects of casting 6 13 1 1

Total 75 110 10 08

198

pattenmaking,core making, moulding, melting&pouring andcleanin& Inspection

1.5 Draw the flow sheet of a foundry plant.

2 Patterns2.1 State the functions of a pattern:

2.2 List various pattern making material such as

i) Wood

ii) Metal

iii) Plaster of paris,

iv) Wax,

v) Quick setting compounds.

2.3 State the relative advantages and limitations of the abovematerials.

2.4 Mention the types of patterns such as

i) Single piece,

ii) Two piece/multi piece,

iii) Loose piece,

iv) Gated,

v) Match plate,

vi) Cope and drag pattern,

vii) Skeleten pattern,

viii) Follow board,

ix) Sweep,

x) Master pattern

2.5 Define pattern allowance.

2.6 Explain various pattern allowances.

i) Shrinkage,

ii) Machining,

iii) Draft,

199

iv) Distortion,

v) Mould wall movement.

2.7 State the importance of colour coding used on pattern.

2.8 Give the colours used for

i) Machined,

ii) Unmachined,

iii) Loose piece,

iv) Core print,

v) Parting surface.

3. Moulding Sands3.1 State the basic ingradients of molding sand.

a) Sand grains b) Water c) Binder

3.2 State different types of sands used in foundry.

a) Silica b) Zircon c) olivine d) chromite

3.3 Define the terms - Natural sand, Synthetic sand

3.4 State the purpose of sand conditioning

3.5 Explain the properties of a good moulding Sand such as

i) Green, dry, hot, Tensile, Compressive and shearStrengths

ii) Permeability.

iii) Refractoriness.

iv) Flow ability.

v) Cohesiveness.

vi) Adhesiveness.

vii) Thermal Stability.

viii) Thermal expansion.

ix) Collapsibility.

x) Reusability.

xi) Moldability.

200

xii) Compactability.

3.6 Define the term Clay and list different clays

3.7 Explain the effects of grain size, moisture content and claycontent on the properties of moulding sand

3.8 Write down the composition of

i) Green Sand,

ii) Dry sand,

iii) Loam sand,

iv) Core sand.

3.9 State the use of

i) Facing sand,

ii) Parting sand,

iii) Back up sand

3.10 Define the term Sand additive

3.11 State the function of the additives

4. Cores4.1 Define the term core

4.2 State the functions of cores

4.3 State the properties of core sand.

4.4 List the ingredients in core sand.

4.5 Explain the process of core making.

i) Core making,

ii) Core backing

iii) Finishing and sizing of cores.

iv) Core assembly,

4.6 State the function of chaplets.

5. Molding processes5.1 Explain the process, application and limitations of

i) Green sand molding,

201

ii) Dry sand molding,

iii) Core sand molding,

iv) Loam molding,

v) Pit and floor moulding

vi) Skin dried molding.

5.2 Distinguish between Green sand molding & dry sand molding.

5.3 Explain the following casting processes their application andlimitation. (Briefly)

i) Permanentmould casting.

ii) Die casting hot chamber, Cold chamber, Goose neck type,

iii) Centrifugal casting. Semi centrifugal, True centrifugal,Centrifuging

5.4 Distinguish between hot chamber & cold chamber die casting.

5.5 Distinguish between true centrifugal & semi centrifugal.

5.6 Explain the following processes..

a) Shell moulding.

b) Investment casting - Lost wax process.

c) Carbon dioxide process.

d) Graphite mould casting.

e) Hot box process

f) No bake process.

g) Cold Box Process.

h) Replicast / Full mold process.

i) V - Process.

j) Cement bonded molds.

k) Squeeze casting.

5.7 state the importance of mould and core coatings.

6. Hand moulding tools and equipment6.1 Draw the neat sketches of the following hand moulding tools.

202

i) Mould boxes - cope - drag- cheek.

ii) Peen and Butt rammers,

iii) Cleaners,

iv) Riddle,

v) Gate cutter,

vi) Swab,

vii) Bellows,

viii) Vent wire,

ix) Trowel,

x) Mould board.

6.2 State the uses of the above tools.

7. Machine moulding Equipment7.1 State the advantages of machine moulding

7.2 List the molding machines

i) Jolt machine

ii) Squeezer.

iii) jolt-squeeze Roll over draw.

iv) Mold or Core blower.

v) Sand Slinger,

7.3 Explain with neat sketch the operation of

a) Jolt-squeeze Roll over draw. b) Sand Slinger.

8. Pouring and feeding of casting8.1 Draw a diagram for feeding system of a casting:

8.2 Explain the function of pouring basin Sprue. Runner.Gate. Riser.

8.3 State the effect of

i) Turbulence - Laminar steady flow

Ii) Pouring rate.

Iii) Pouring temperature.

203

iv) Solidification characteristics,

v) Freezing temperature range,

8.4 Define Gating Ratio.

8.5 Define Pressurised&unPressurised gating systems.

8.6 Give the suitable gating ratios for different applications.

8.7 Determine the dimensions of sprue, runner and gate for simplecasting process.

8.8 List the different types of gating systems

8.9 State the advantages and limitations of - Top gating, Bottomgating and parting line gating

8.10 State the functions of Riser in casting.

8.11 Describe the factors involved in Riser design

i) Modulus (Location of riser)

ii) Size and shape of riser

iii) Chronivov's principle,

iv) Importance of (V/A) ratio.

8.12 Types of Risers - Open, Blind

8.13 State the caine's principle

8.14 Define directional & progressive soldification.

8.15 Explain the factors affecting directional solidification.

9. Defects in Castings9.1 List out various casting defects:

a) Shifts b) blow holes c) Pin holes d) Porosity

e) Shrinkage cavity f) metal penetration. g) Rough surface.

h) Scabs i) hot tears j) cold shuts. k) misrun

9.2 Explain the above defects with remedial measures

204

COURSE CONTENTS

1. INTRODUCTION: Foundry as a production process,advantages and Limitation of foundry. Type of foundries, Basicsteps involved in a sand casting process such as patternmaking, core making, moulding, melting, pouring and cleaning.

2. Patterns: Pattern and its function in a foundry, Pattern makingmaterials, Their relative advantages and limitations, Types ofpatterns, Pattern allowances, Pattern colour codes: Machined,unmachined, core prints, loose piece, parting line

3. Moulding Sands Sand moulds: Green and dry sand moulds,Properties of sand, shatter Index value, sand testing methods,Ingredients of a moulding sand, Sand grains, Effect of clay onstrength, expansion , permeability and water content. Sandconditioning its effect on mould, Additives, Types of sands

4. Cores: Function of cores, core sands, core ingredients, coreoils, core binders, Properties of core sands, Core making.Finishing of core & sizing core assembly, use of chaplets.

5 Molding processes :i) Sand moulding : Green sand, dry sand,core sand moulds, loam moulds, pit and floor moulding, skindried molds, Special casting processes, applications,advantages and limitations, High pressure molding, hot boxprocess. No bake process, cold box process, replicastprocessfluid sand process , V- process, cement bonded molds,squeeze casting (Briefly),

6. Hand moulding tools and equipment: Mould boxes, peenand butt rammers cleaner, riddle, gate cutter, swab, bellows,draw spike, vent wire, mould board, trovel, (Sketches andpurpose only)

7. Machine moulding equipment: Description and applicationof jolt squeezer, sand slinger roll over moulding machines,mould or core blower.

205

8. Pouring and feeding of casting: Pouring, filling the mould.Factors involved, Shrinkage, solidification characteristicsfreezing temperature range & fluidity, Feeding system, Spruedesign, Runners, eliminating slag and dross, Types of Gates,Their applications. Design of gate, Risers : Function, factorsinvolved in the design and their importance, Moulding of riser,Chronivov's rule & Caine's method, Factors effecting riserefficiency, Chills, their use, simple Progressive and directionalsolidification, Fluidity - factors.

9. Deffects in casting : Moulding defects, - shifts, blow holes,pin holes, shrinkage cavity, Porosity, metal penetration andrough surface, Scabs, hot tears, cold shuts and misrun,warpage of casting, swell, slag holes.

TEXT BOOK:1. Principles of metal casting -by Heine and Rosenthal

REFERENCE BOOKS1. Foundry Technology - by P.K Jain

2. Foundry Technology - by M. Lal, khanna Publishers.

*****

206

OBJECTIVESOn the completion of the subject ,the student should be able tounderstand,

1. Heat treatment of steels:

1.1 Define Heat Treatment.

1.2 State the objectives & purposes of Heat Treatment.

1.3 List the Heat treatment processes.

1.4 Know about the phase transformations on heating of steels.

1.5 Know about the decomposition of austenite on cooling.

HEAT TREATMENT TECHNOLOGYSubject Title : Heat Treatment Technology.Subject Code : MET-405Periods per week : 05Total periods per semester: 75




1. Heat treatment of plaincarbon steels 18 26 2 2

2. Hardenability 6 10 - 1

3. Grain size 6 10 - 1

4. Alloy steels and theirHeat Treatment 13 19 3 1

5. Special Heat TreatmentTechniques & defects 13 19 3 1

6. Heat Treatment furnaces 8 10 - 1

7. Furnace atmospheres 3 3 1 -

8. Heat Treatment ofNon-ferrous Metals 8 13 1 1

Total 75 110 10 08

207

1.6 Define isothermal transformation.

1.7 Explain the construction of Time Temperature TransformationDiagrams.

1.8 List out the factors affecting position of TTT curve.

1.9 Define Critical Cooling rate.

1.10 Explain the superimposition of continuous cooling curves.

1.11 Define a) Pearlite b) Bainite & c) Martensite

1.12 Explain the mechanism of austenite to

a. Pearlitic transformation

b. Bainitictransformation

c. Martensitic transformation.

1.13 State the effect of carbon content on Maximum hardness ofsteel.

1.14 Define and state the purpose of

a) Annealing

b) Normalizing

c) Hardening

1.15 Mention the Annealing, Normalizing and Hardeningtemperatures of eutectiod, hypo eutectiod, hyper eutectiodsteels.

1.16 Explain a) Annealing

b) Normalizing

c) Hardening processes.

1.17 List out the types of annealing.

1.18 Draw the microstructures at various temperatures of annealing

1.19 Define & state the purpose of spheroidizing annealing

1.20 Explain the spheroidizing process.

1.21 Draw the spheroidized structure.

208

1.22 Draw the normalized microstructure.

1.23 Compare annealing & normalizing.

1.24 Mention the stages of quenching.

1.25 Draw the hardened microstructure.

1.26 Define & state the purpose of Tempering

1.27 Explain the Tempering process.

1.28 Describe the theory of Tempering. .

1.29 State the effect of Tempering on microstructure and mechanicalproperties.

1.30 Describe the types of tempering

1.31 Define retained austenite.

1.32 Define Temper Embrittlement and state the causes andremedies..

2. Hardenability:

2.1 Define hardenability

2.2 Differentiate Hardness and Hardenability.

2.3 State different Quenching Media.

2.4 Define the cooling power of Quenching Media.

2.5 List out merits & demerits of each quenching medium.

2.6 Define critical diameter & ideal critical diameter.

2.7 Draw the relationship between critical diameter & ideal criticaldiameter.

2.8 Determine the relationship between ideal critical diameter,chemical composition & hardenability.

2.9 Explain the Jominey end - quench test .

2.10 State the use of Jominey end quench test

3. Grain size

3.1 Define grain size.

209

3.2 Determine the grain size by carburising method.

3.3 Determine the grain size by ASTM comparative Method..

3.4 State the measurement of Austenite grain size by Heyn'sintercept method and Jefferies planimetric method.

4 Heat Treatment of Alloy steels:

4.1 State the purpose of alloying.

4.2 Mention the effect of alloying elements on the Fe-Carbidediagram & hardenability.

4.3 Classify the alloying elements which tend to

a. form carbides.

b. graphitise the carbides

c. stabilize the austenite

d. stabilise the Ferrite

4.4 Give the composition, properties & applications of

a. Nickel steels.

b. Chromium steels

c. Manganese steels

4.5 Define stainless steels.

4.6 Classify the stainless steels.

4.7 State the composition, properties and applications of

a. Ferritic

b. Austenitic

c. Martensitic stainless steels.

4.8 State the heat treatment process for ferritic, austenitic andmatensitic stainless steels.

4.9 Know about sensitisation&stabilisation.

4.10 List the causes and remedies of sensitisation.

210

4.11 Know about composition, properties and applications ofMaraging steels.

4.12 Define tool steels.

4.13 Give the composition of

a) Water hardening steels b) High-speed tool steels.

4.14 List the properties of high-speed tool steels.

4.15 Give the heat treatment procedure for tool steels.

4.16 Explain the heat treatment cycle for high-speed steels.

4.17 Define secondary hardening.

4.18 Know the Special cutting materials.

4.19 Know the chemical composition & properties of stellite.

4.20 Know the chemical composition, microstructure & propertiesof cemented carbides.

5.0 Special heat treatment techniques:

5.1 Define case hardening.

5.2 Know the case hardening techniques.

5.3 Define

a) carburising

b) Nitriding

c) Cyaniding

d) Flame Hardening

e) Induction Hardening

5.4 Sate the types of carburising Techniques.

5.5 Explain a) Packcarburising,

b) Liquidcarburising

c) Gascarburising.

5.6 Enumerate the advantages & disadvantages of carburising.

211

5.7 List the applications of carburised steels

5.8 Draw the microstructure of carburised steel.

5.9 Explain the post carburising heat treatment.

5.10 Explain the nitriding process.

5.11 Know the effect of nitriding on properties of steels.

5.12 State the applications of nitriding.

5.13 Know about white layer.

5.14 Explain the cyaniding process.

5.15 Understand the composition of cyanide bath.

5.16 Enumerate advantages of cyaniding.

5.17 Explain the flame hardening process.

5.18 Explain the induction hardening process.

5.19 Define Austempering&Martempering

5.20 Explain the austempering process.

5.21 Mention the effect of austempering on properties of steels.

5.22 Explain the martempering process.

5.23 Mention the effect of martempering on properties of steel.

5.24 Know about defects in heat treated products.

5.25 Mention the causes and remedies of low hardness, soft spots,oxidation, decarburisation, overheating, burning, quenchcracks, distortion and warping.

5.26 Know about Widmanstatten structure.

6.0 Heat Treatment furnaces

6.1 Know about Heat treatment furnaces:

6.2 Classify the heat-treating furnaces based on design and theiruse

6.3 Explain the working principle of the following furnaces with aneat sketch - Muffle, Salt bath, Bogie type, pit & rotary hearth.

212

7.0 Furnace atmospheres

7.1 Define the controlled atmosphere.

7.2 Know about the necessity of maintaining controlledatmosphere.

7.3 Know about the Exothermic and Endothermic atmosphere.

7.4 State the methods of controlling Furnace atmosphere.

8.0 Heat treatment of Non-ferrous Metals:

8.1 Know about the Heat treatment of Al-Cu alloy.

8.2 Explain solution treatment with the help of Al - Cu phase diagram

8.3 Explain precipitation hardening.

8.4 Explain the theory of Age-hardening.

8.5 List the Al - alloys respond to precipitation hardening

8.6 State the Heat treatment process for Brass and Bronzes

COURSE CONTENTS

1.0 Heat Treatment of Plain Carbon Steels : Introduction,Transformation of Austenite to pearlite, bainite, martensite,construction of TTT curves and their applications, types of heattreatment processes- Annealing, Normalising, Hardening andTempering, Temper embrittlement.

2.0 Hardenability : Definition, difference between hardness andharden ability, critical & ideal critical diameter, calculation ofideal critical diameter, jominey end quench test process andits uses,.

3.0 Grain Size: Effect of grain size on properties of steel, Grainsize determination by.Carburising method, ASTM Comparativemethod heyn's intercept method, Jefferies planimetric method,.

4.0 Alloy Steels & their Heat treatment: Definition, Purpose ofalloying, Effect of alloying elements on Fe - C diagram.

213

Classification of alloying elements, Nickel steels, Manganesesteels, Chromium steels, Stainless steels, Tool steels heattreatment, properties and uses. Maraging steels.

5.0 Special heat - treatment techniques and defects in heat treatedproducts :Introduction, Chemical heat treatments -Carburising,Nitriding, Cyaniding,. Surface hardening treatments-Flame andInduction hardening. Austempering, Martempering and sub-zerotreatment.Defects in the Heat treatment.

6.0 Heat treatment Furnaces:

Classification according to design and use, Continuous andBatch furnaces.

7.0 Furnace Atmospheres:Introduction, definition, need ofcontrolled atmosphere, Types of furnace atmospheres -Exothermic and Endothermic atmosphere, Method of controllingof controlled atmospheres.

8.0 Heat treatment of Non-ferrous Metals: Introduction,Precipitation hardening of Al-Cu alloys, Heat treatment ofBrasses and Bronzes.

REFERENCE BOOKS:

1. Heat Treatment Principles and Techniques - by T.V.RajanSarma, AshokSharma.

2. Engineeeering metallurgy Part I - by Raymond Higgins

3. Metallurgy for Engineers - by E.C. Rollason ELBS.

4. Physical metallurgy and Heat Treatment - byLakhtin

5. Introduction to physical metallurgy - Sydney H. Avener

6. Physical metallurgy for engineers - Clark&Warney

7. Materials science and Metallurgy - kodigere.

*****

214

STEEL MAKINGSubject Title : Steel MakingSubject Code : MET-406Periods / Week : 04Periods / Semester : 60



1. Introduction ofsteel making 8 16 2 1

2. Oxygen steel making 10 16 2 1

3. Electric furnaces 8 16 2 1

4. vacuum treatment of liquid steel 8 13 1 1

5. Secondary steel makingprocess 12 13 1 2

6. Casting pit practice 08 13 1 1

7. Ferro - Alloys 6 13 1 1

Total: 60 110 10 08

OBJECTIVESAfter the completion of these topics the student should be ableto understand the

1.0 Introduction of steel making.1.1 History Of Steel Making: Cementation and crucible processes.

1.2 Know the wrought iron making process.

1.3 State the principle of Steel making.

1.4 Chemistry of Steel Making processes, Theories of slag.Oxidation of Si, Mn and C.

1.5 List the steel making processes.

1.6 List out the raw materials required for steel making.

215

1.7 State the principle of Bessemer process.

1.8 State the limitations of Bessemer process.

1.9 Define the mixer.

1.10 Classify the mixers.

1.11 Differentiate the Active mixer & inactive mixer.

1.12 Classify the open-hearth process

1.13 State the general principles of open hearth furnace

1.14 State the advantages of Open Hearth Process as comparedto Bessemer process.

1.15 List the recent trends in open hearth process.

i) Ajax ii) Tandem iii) tilting open hearth iv) Twin hearth

2.0 Oxygen steel making:2.1 State the principles of Oxygen Steel making Process.

2.2 List Oxygen Steel making processes

2.3 Advantages of using pure Oxygen in Steel making.

2.4 State the Raw materials for L.D. Process

2.5 Explain the constructional details of converter & design of thelance.

2.6 Know the lining of the converter.

2.7 Explain the operation of L.D. Process with chemical reactions.

2.8 Understand the sequence of elimination of impurities

2.9 Appreciate the advantages & uses of L.D. process.

2.10 Understand dephosphorization, desulphurization anddeoxidation

2.11 Explain stainless steel making process by L.D.

2.12 Understand the developments in L.D.process - LD-AC, LAMprocess, Kaldo, Rotor and OBM.

3.0 Electric Furnaces:3.1 Classify the electric furnaces.

3.2 State the principle of Arc furnace.

216

3.3 List the raw materials.

3.4 State the sequence of the charging.

3.5 Know the electrode material.

3.6 Explain the construction and lining details of furnace.

3.7 Explain the melting practice for the production of carbon steels

3.8 Define carbide slag.

3.10 State the importance of carbide slag.

3.11 Brief outline of manufacture of alloy steels.

3.12 Appreciate advantages & disadvantages of Arc furnace.

3.13 Know the use of gaseous oxygen in Electric Arc furnace

3.14 Explain stainless steel making by electric arc furnace (Rustless Process)

3.15 State the principle of induction furnace.

3.16 Explain the melting practice in Induction furnace

3.17 Appreciate the advantages of induction furnace

4.0 vacuum treatment of liquid steel4.1 Know the gasses and inclusions in liquid steel

4.2 State the objectives of degassing

4.3 Classify the degassing processes.

4.4 Explain the ladle degassing, steam degassing, circulationdegassing ( R-H &D - H process)

5.0 Secondary steel making processes:5.1 Need for production of high quality steels

5.2 State the objectives of secondary steel making.

5.3 Classification of Secondary steel making processes.

5.4 Explain Furnace based processes-A.O.D process.

5.5 Explain Ladle based processes-Ladle furnace.

5.6 Explain Re melting processes-E.S.R. and V.A.R.

5.7 Recent trends in steelmaking processes.

217

5.8 Understand the Hybrid Steel making processes, EAF - OSM&SLP and EOF process.

5.9 understand the Continuous steel making processes: WOCRA,IRSID, and DIOS

6.0 Casting pit practice6.1 Classify the ingot moulds.

6.2 Know the ingot mould material.

6.3 List the Methods of teeming.

6.4 Explain various methods of teeming.

6.5 Classify the steels basing on gas evolution - killed, semi killed,rimmed & capped steels

6.6 List the ingot defects.

6.7 Explain various ingot defects with remedial measures.

6.8 Define the continuous casting.

6.9 Appreciate the advantages of continuous casting.

6.10 State the Principle of Continuous Casting

6.11 State junghan's principle

6.12 Classify the continuous casting machines.

6.13 Explain the vertical mold - horizontal discharge type Machine.

6.14 Explain the curved mold continuous casting machine and stateits advantages

6.15 List the problems in the production of ingots by CCM.

7.0 Ferro alloys7.1 Define the term Ferro-alloy

7.2 State the types of Ferro alloys

7.3 State the purpose of using Ferro-alloys

7.4 Explain manufacturing process of Ferro-silicon

7.5 Identify the applications of Ferro-silicon in iron and steel industry

218

COURSE CONTENTS1.0 Introduction of steel making : Wrought Iron, Bessemer

Process, Mixers, Raw Materials, Chemistry of Steel Making,Acid and Basic steel Making.General principles, Regenerationprinciple, Classif ication, Basic open Hearth process,construction, Lining, operation Reactions, Tilting O.H. Process,Twin hearth, Ajax, Tandem furnace

2.0 Oxygen Steel Making: L-D process: Principles, RawMaterials, Lining of the converter, Blow period, lance, carbonsteel Making; stainless steel Making, Advantages anduses.Developments in LD - LDAC - LAM - KALDO - ROTOR.

3.0 Electric Furnaces: Principles of arc Furnace, classification,Raw materials sequence of charging, Electrode Material,construction of arc furnace, Melting practice, single and doubleslag practice carbide slag, Use of oxygen lancing, Advantagesand disadvantages, Melting practice in Induction furnace,Advantages of induction Furnace.

4.0 VACCUM TREATMENT OF LIQUID STEEL: Gasesdissolved in liquid steel, Function of degassing plant Ladledegassing, stream degassing, circulation degassing, (R.H&D.Hprocess)

5.0 SECONDARY STEEL MAKING PROCESS: AOD process,Ladle furnace, ESR process, vaccum Arc melting,

6.0 CASTING PIT PRACTICE: Classification of Ingot moulds,Mould materials, methods of teeming, killed, semi-killed,Rimmed, capped steels, Ingot defects.Continuous casing ofsteel:Principle, Advantages, Junghan'spriciple, Curved type;Vertical type - Horizontal discharge CCM

7.0 FERRO - ALLOYS: Definition, types, purpose, manufactureof ferro - silicon, its applications

REFERENCE BOOKS 1. Introduction of modern steel making -- R.H. Tupkary 2. Manufacture of iron and steel Vol.II -- G.R.Bashforth 3. Elements of metallurgy -- Dr. Swaroop 4. Iron and steel making theory and practice -- Ahindra Ghosh &

Chatterjee*****

219

MATERIAL TESTING LAB PRACTICE-ISubject Title : Material Testing Lab Practice - ISubject Code : Met-407Periods/Week : 03Periods/Semester : 45

TIME SCHEDULES.No Experiment Title No. of Periods1 Tensile test 15

2 Brinell hardness test 06

3 Rockwell hardness test 06

4 Rockwell superficial hardness test 09

5 Impact test 09

Total periods 45

OBJECTIVESUp on the completion of the course the student shall be ableto:

1.0 Material testing Laboratory - Understand the variousmaterial testing methods.

1.1 Define the various properties of materials such as: elastic limit,yield stress, Ultimate stress, breaking stress, percentageelongation, ,percentage reduction in area

1.2 Define Brinell hardness number of given material

1.3 Conduct experiments on ferrous and non ferrous materials byusing Brinell hardness tester

1.4 Conduct experiments on ferrous and non ferrous materials byusing Rockwell hardness tester

1.5 Conduct experiments on given thin materials by using Rockwellsuperficial hardness tester

220

1.6 Appreciate the importance of various mechanical propertiessuch as hardness, impact strength.

1.7 Perform tests to determine the impact strength by using Izodand charpy test specimens

Key competencies to be achieved by the studentTitle of the experiment Key competency1. Tensile test 1.Fix specimen in the jaws of the

machine

2.Fit strain gauge to the specimen

3.Apply load gradually on thespecimen

4.Record load, elongation,diameter without error

5.Plot the graph stress vs. strain

2. Brinell hardness test 1.Place the specimen on themachine at correct location

2.Make indent on the specimenproperly

3.Measure diameter of indentationand calculate hardness number

3. Rockwell hardness test 1. Place the specimen on themachine at correct location

2.Identify suitable scale, indenterand load for the specimen


4.Read the scale for hardnessnumber

221

4. Rockwell superficial 1. Place the specimen on the hardness test machine at correct location

2.Identify suitable indenter for thespecimen


4.Measure diameter of indentationand Calculate hardness number

5. Impact test 1.Prepare specimen by making Vnotch at the required height

2.Fix specimen on the machine

3.Release load to hit thespecimen and record impactenergy

COURSE CONTENT1. Determination of yield strength, ultimate strength, percentage

reduction in area, percentage elongation, elastic limit, breakingstress, stress-strain curve by using UTM

2. Determine the Brinell hardness number of ferrous and nonferrous materials by using Brinell hardness tester.

3. Determine the Rockwell hardness number of ferrous and nonferrous materials by using Rockwell hardness tester.

4. Determine the hardness of thin specimens such as razorblades, hacksaw blades, thin sheets using Rockwell superficialhardness tester.

5. Determination of impact strength of the material using Izod andCharpy tests.

*****

222

HEAT TREATMENT LAB PRACTICESubject Title : Heat treatment lab PracticeSubject Code : MET-408Periods / Week : 06Periods / Year : 90

TIME SCHEDULES.No. Major Topics No. of

Periods1 Annealing 15

2 Hardening 15

3 Normalizing 15

4 Tempering 12

5 Jominey-end quench test 18

6 Precipitation hardening 15

TOTAL 90


1.0 Conducting annealing heat treatment of given steelsample and study the properties

1.1 Define Annealing

1.2 Types of annealing process

1.3 Working of Muffle furnace

1.4 Handling of apparatus

1.5 Observing and manipulating of furnace temperature

1.6 Cooling of specimen in the furnace

1.7 Microstructure analysis of annealed specimen

1.8 Draw the microstructure of annealed steel sample

223

2.0 Conducting hardening process and study the effect ofquenching media

2.1 Define hardening

2.2 List of quenching media

2.3 Identify the parts of muffle furnace

2.4 Calibrate the temperature of the furnace

2.5 Handling the specimen before quenching by using fixtures

2.6 Analysis of Microstructures of hardened specimens by usingdifferent quenching media

2.7 Observe the phases of microstructures

2.8 Draw the microstructure

2.9 Recording the hardness values before hardening and afterhardening


3.0 Conduct the normalizing process and study the propertiesof a given sample of steel

3.1 Define normalizing

3.2 Need of normalizing of annealed specimens

3.3 Recording of normalizing temperature

3.4 Draw the microstructure of normalized steel

3.5 Identify the phases present in normalized steel samplemicrostructure

4.0 Conduct the tempering heat treatment process and studythe tempering temperature on properties of steel

4.1 Define tempering

4.2 Need of tempering heat treatment for hardened steels

4.3 Types of tempering processes

4.4 Draw the microstructures of tempered steel specimens

4.5 Study the structural changes during tempering process

224

5.0 Determine the hardenability by using jominey-end quenchtest apparatus.

5.1 Define hardenability

5.2 Specimen dimensions of sample used in jominey end quenchtest

5.3 To know the critical diameter

5.4 Handling of equipment

5.5 Maintaining the constant pressure of water through an orifice

5.6 To maintain temperature of water

5.7 To know maintaining of distance between orifice and end ofsteel bar

5.8 Plot the hardenability curve

6.0 Conduct precipitation hardening process of aluminiumalloys and study the effects of precipitates.

6.1 Define precipitation hardening

6.2 Types of precipitates formed during precipitation hardening

6.3 To know the over aging

6.4 Effect of precipitates during age hardening

6.5 To know the time and temperature for formation of precipitates

6.6 To know about double aging

Title of the experiment Key competency1.Annealing 1. Calibration of furnace

temperature

2. Load the sample

3. Cooling the sample in furnaceatmosphere

2.Hardening 1. Selecting of quenching media

2. Soaking of sample in furnacetemperature

225

3. Holding of quenching media

3.Normalizing 1. Recording of normalizedtemperature

2. Soaking of sample in furnace

3. Cooling of sample in open air

4.Tempering 1. Selecting of hardened sample

2. Soaking of sample in thefurnace

3. Air cooling of sample

5.Jominey-end quench test 1. Hardening of the sample

2. Quenching of sample byusing fixtures

3. Maintain the watertemperature and pressure

6.Precipitation hardening 1. Selection of sample suitablefor the process

2. Applying artificial or naturalageing

3. observe the microstructuresof precipitate hardenedsample

COURSE CONTENT1. Conducting annealing heat treatment of given steel sample and

study the properties

2. Conducting hardening process and study the effect ofquenching media

226

3. Conduct the normalizing process and study the properties of agiven sample of steel

4. Conduct the tempering heat treatment process and study thetempering temperature on properties of steel

5. Determine the hardenability by using jominey-end quench testapparatus.

6. Conduct precipitation hardening process of aluminium alloysand study the effects of precipitates.

*****

227

FOUNDRY LAB PRACTICESubject Title : Foundry Lab PracticeSubject Code : MET-409Periods per week : 03Periods per semester: 45

TIME SCHEDULES.No List of Experiments No. of Periods1. Standard sand specimen 03

2. Green Compression & Green Shear Dry Compression & Dry Shear strength 06

3. AFS Grain Fineness number 06

4. Hardness of the moulding sand 06

5. Moisture content determination 06

6. Preparation of mould cavity 12

7. Preparation of sand core and assembling in the cavity. 06

TOTAL 45


1.0 Prepare a standard sand specimen1.1 Define the term moulding sand.

1.2 List the constituents of moulding sand.

1.3 State the properties of a good moulding sand

1.4 Explain the function of sand rammer

1.5 prepare a suitable sand mixture



1.8 Perform the precise operations to prepare a standard sandspecimen

228

1.9 List the Precautions and safety procedures


2.0 Determination of Green compression, Green shear, Drycompression & Dry shear strength of a given sand mixtureusing given apparatus

2.1 Explain the properties of moulding sand

2.2 Explain the importance of green & dry strength of the mouldingsand.

2.3 Differentiate between compressive loading and shear loading

2.4 Prepare a suitable sand mixture

2.5 Identify the parts of a universal sand testing machine



2.8 Perform the precise operations to determine the compressionand shear strength of a sand mixture

2.10 Record various observations

2.11 State the effect of temperature on the strength.

2.12 Draw the graph between the temperature and strength.

2.13 Explain the need and scope of the Experiment

3.0 Determination of AFS Grain Fineness number of a givensample of sand mix using given apparatus

3.1 Explain the importance of size and shape of sand grains

3.2 State the effect of size and shape of sand grains on theproperties of sand mould.

3.3 Identify various parts of sieve shaker.

3.4 Arrange the set sieves in the order



3.7 Perform precise operations on sieve shaker to record variousparameters

229

3.8 Determine the AFS Grain Fineness Number from theobservations.


4.0 Determination of the hardness of a given sample of sandmix.

4.1 Explain the importance of sand hardness

4.2 Identify the parts hardness tester.



4.5 Perform precise operation of hardness tester on sandspecimen and mould cavity and record the observations


5.0 Determination and importance of moisture content of thegiven sand mixture

5.1 State the importance of moisture content in the sand mix.

5.2 Explain the methods of determination of moisture content

5.3 State the principle on which rapid moisture teller works



5.6 Perform precise operations on rapid moisture teller

5.7 Observe and record the readings


6.0 Prepare a green sand mould cavity with the given pattern6.1 Define pattern and List different patterns

6.2 List various hand moulding tools for preparation of mould cavity

6.3 Prepare suitable sand mixture

6.4 Explain the procedure for preparation of sand mould

6.5 Handle the tools

6.6 Manipulate the tools

6.7 Prepare a precise mould cavity

230

Key Competency

1. Weighed quantities of ingredients ofsand

2. Place the tube in the base of therammer

3. Observe whether the tip coincides withzero or not

4. Measure the length of the specimen

1. identify the compressive & shearheads

2. Apply the load gradually3. Record the reading carefully after

specimen breaks

1. Arrange the set of sieves in order2. weigh the quantities of sand retained

on the sieves after shaking3. Tabulate the readings and calculate

the fineness number

Experiments

Standard sand specimen

Green Compression & GreenShearDry Compression & Dry Shearstrength

AFS Grain Fineness number

6.8 Explain the need of the experiment

7.0 Prepare a sand core and assemble in the mould cavity7.1.1 Define core and state the function of core

7.1.2 List different types of cores

7.1.3 State the ingredients of a core sand mixture

7.1.4 Explain the procedure for preparation of sand core

7.1.5 Handle the tools

7.1.6 Manipulate the tools

7.1.7 Prepare a precise sand core and assemble it in the mouldcavity

7.1.8 Explain the need of the experiment.

KEY Competencies to be achieved by the student

231

1. Operate the tester2. Apply load gradually3. Observe and record the reading

1. Operate the moisture teller2. Add CaC2 powder and shake

vigorously3. Observe and record the reading

1. Identify various tools2. operate the tools precisely3. with drawl of pattern4. Cut the gates and runners5. finish the cavity & close the boxes

1. Identify the tools required2. operate the tools carefully3. withdraw the finished core4. Assemble the core in the cavity

Hardness of the moulding sand

Moisture content determination

Preparation of mould cavity

Preparation of sand core

COURSE CONTENT1. Preparation of a standard sand specimen.

2. Determination of green compression, shear & Dry compressionand shear strength of a given sand mixture by using universalsand testing machine

3. Determination of AFS Grain Fineness Number of given sandmixture by using a standard sieve shaker

4. Determination of hardness of the given sand mixture by usinghardness tester

5. Determination of moisture content of the given sand mixtureby using rapid moisture teller .

6. Preparation of a green sand mould cavity with the given pattern.

7. Preparation a sand core and assembly of the core in the mouldcavity.

*****

232

PROGRAMMING IN C LAB PRACTICESubject Title : Programming in C Lab PracticeSubject Code : MET-410Periods per Week : 04Periods per Semester : 60

LIST OF EXPERIMENTS1. Exercise on structure of C program

2. Exercise on Keywords and identifiers

3. Exercise on constants and variables

4. Execution of simple C program

5. Exercise on operators and expressions

6. Exercise on special operators

7. Exercise on input and output of characters

8. Exercise on formatted input and output

9. Exercise on simple if statement

10. Exercise on if..else statement

11. Exercise on else..if ladder statement

12. Exercise on switch statement

13. Exercise on conditional operator (? :)

14. Exercise on while statement

15. Exercise on for statement

16. Exercise on do..while statement

17. Exercise on one dimensional arrays

18. Exercise on two dimensional arrays

19. Exercise on structure

20. Exercise on array of structures.

233


Periods)

1 Exercise onstructure of Cprogram

2 Exercise onKeywords andidentifiers

3 Exercise onconstants andvariables

4 Execution ofsimple C program

5 Exercise onoperators andexpressions

Competencies

For a given C program,identify the different buildingblocks

For a given C programidentify the keywords andidentifiers

For a given C programidentify the constants andvariables

Execute a simple C program

Write a C program that usesdifferent arithmeticoperators

Key competencies

Identify differentbuilding block in a Cprogram

Identify differentkeywordsCheck whether thekeywords are inlowercaseDifferentiate identifiersand keywords

Identify the constantsIdentify the variablesDeclare variables withproper namesKnow the assignmentof values to variables

Acquaint with Cprogram editingCompile the programRectify the syntacticalerrorsExecute the program

Identify differentarithmetic operatorsBuild arithmeticexpressionsIdentify the priorities ofoperatorsEvaluate arithmeticexpressionCompile the programRectify the syntacticalerrorsExecute the program


234

6 Exercise ons p e c i a loperators

7 Exercise on inputand output ofcharacters

8 Exercise onformatted inputand output

9 Exercise onsimple ifstatement

Write a C program thatuses special operators

Write a C program forreading and writingcharacters

Write a C program usingformatted input andformatted output

Write a C program usingsimple if statement

Check the output for itscorrectness

Identify different specialoperatorsBuild expressions usingspecial operatorsCompile the programRectify the syntacticalerrorsExecute the programCheck the output for itscorrectness

Know the use of getchar()functionKnow the use of putchar()functionCompile the programRectify the syntacticalerrorsExecute the programCheck whether the correctoutput is printed for thegiven input

Know the use of formatstring for different types ofdata in scanf() function Know the use of formatstring for different types ofdata in printf() functionCheck whether the data isread in correct formatCheck whether the data isprinted in correct format

Build a relationalexpressionUse the if statement fordecision makingRectify the syntax errorsCheck the output forcorrectness

235

10 Exercise onif..else statement

11 Exercise onelse..if ladderstatement

12 Exercise ons w i t c hstatement

13 Exercise onc o n d i t i o n a loperator

14 Exercise onwhile statement

Write a C program usingif..else statement

Write a C program usingelse..if ladder statement

Write a C program usingswitch statement

Write a C program using( ? : ) conditional operator

Write a C program usingwhile statement

Build a relationalexpressionUse the if..else statementfor decision makingRectify the syntax errorsCheck the output forcorrectness

Use else..if ladderstatements with correctsyntaxRectify the syntax errorsDebug logical errorsCheck the output forcorrectness

Use switch statement withcorrect syntaxIdentify the differencesbetween switch and else..ifladderRectify the syntax errorsDebug logical errorsCheck the output forcorrectness

Build the three expressionsfor conditional operatorUse conditional operatorwith correct syntaxRectify the syntax errorsDebug logical errorsDifferentiate conditionaloperator and if..elsestatement

Build the terminationcondition for loopingUse while statement withcorrect syntaxCheck whether correctnumber of iterations areperformed by the whileloop

236

Rectify the syntax errorsDebug logical errors

Build the initial, incrementand termination conditionsfor loopingUse for statement withcorrect syntaxRectify the syntax errorsDebug logical errorsCheck whether correctnumber of iterations areperformed by the for loopDifferentiate for and whilestatements

Build the terminationcondition for loopingUse do statement withcorrect syntaxRectify the syntax errorsDebug logical errorsCheck whether correctnumber of iterations areperformed by the whileloopDifferentiate do..while,whileand for statements

Create a one dimensionalarray with correct syntaxStore elements into arrayRead elements from arrayValidate boundaryconditions while accessingelements of arrayRectify the syntax errorsDebug logical errorsCheck for the correctnessof output for the given input

Create a two dimensionalarray with correct syntaxStore elements into array

15 Exercise on forstatement

16 Exercise ond o . . w h i l estatement

17 Exercise on oned i m e n s i o n a larrays

18 Exercise on twod i m e n s i o n a larrays

Write a C program usingfor statement

Write a C program usingdo statement

Write a C program tocreate and access onedimensional array

Write a C program tocreate and access twodimensional array

237

19 Exercise onstructure

20 Exercise on arrayof structures

Write a C program usingstructure

Write a C program tocreate an array ofstructures and store andretrieve data from thatarray

Read elements from arrayValidate boundaryconditions while accessingelements of arrayRectify the syntax errorsDebug logical errorsCheck for the correctnessof output for the given input

Define a structure withcorrect syntaxIdentify different membersof a structureDeclare a structure variableAccess different membersof structureObserve the size of thestructureRectify the syntax errorsDebug logical errorsCheck for the correctnessof output for the given input

Define a structure withcorrect syntaxIdentify different membersof a structureDeclare a structure variableCreate an array of structureAccess individual elementof the array of structureAccess different membersof structureRectify the syntax errorsDebug logical errorsCheck for the correctnessof output for the given inputobservations

238

V SEMESTERSCHEME OF INSTRUCTION AND EXAMINATION

(PRACTICAL TRAINING)

No Subject Duration Scheme of Examination Re-

Nature Item Max. marksMarks

1. Practical Viva At the Industrytraining in a 6 Voce 1.Firstmetallurgical Months & Log Assessment 100 Industry or book (at the endallied of 3rd month) Industry 2 .Second

Assessment 100(at the endof 6th month )

At theInstitution

3) Log Book 30

4)TrainingReport 30

5. Seminar on training 40

Total for each semester 300

1. The Industrial training shall carry 300 marks and pass marksis 50%. A candidate failing to secure the minimum marksshould complete it at his own expenses.

2. During Industrial training the candidate shall put a minimum of90% attendance.

*****

239

VI SEMESTERSCHEME OF INSTRUCTION AND EXAMINATION

(PRACTICAL TRAINING)

No Subject Duration Scheme of Examination Re-

Nature Item Max. marksMarks

1. Practical Viva At the Industrytraining in a 6 Voce 1.Firstmetallurgical Months & Log Assessment 100 Industry or book (at the endallied of 3rd month) Industry 2 .Second

Assessment 100(at the endof 6th month )

At theInstitution

3) Log Book 30

4)TrainingReport 30

5. Seminar on training 40

Total for each semester 300

1. The Industrial training shall carry 300 marks and pass marksis 50%. A candidate failing to secure the minimum marksshould complete it at his own expenses.

2. During Industrial training the candidate shall put a minimum of90% attendance.

*****

240

VII SEMESTER

241


VII SEMESTER


/Week Semester


Hours Marks Marks

THEORY

MET-701 Industrial Manage-ment andEntrepreneurship 4 - 60 3 20 80 100

MET-702A WeldingTechnology 5 - 75 3 20 80 100

MET-702B CorrosionEngineering

MET-703 Metal CastingTechnology 5 - 75 3 20 80 100

MET-704 MechanicalMetallurgy 5 - 75 3 20 80 100

MET-705 Non-ferrousExtractiveMetallurgy 5 - 75 3 20 80 100

PRACTICALS

MET-706 Material TestingLab Practice-II - 3 45 3 40 60 100

MET-707 Metal CastingLab Practice - 3 45 3 40 30 100

MET- 708 CAD Lab Practice 3 45 3 40 30 100

MET-709 MetallographyLab Practice -II 6 90 3 40 60 100

MET-710 Project work &Viva-voce - 3 45 3 40 60 100

TOTAL 24 18 630 300 640 1000

242

INDUSTRIAL MANAGEMENT ANDENTREPRENEURSHIP

Subject Title : Industrial Management AndEntrepreneurship




(3 Marks) (10Marks)

1. Principles and functionsof Management 4 08 01 ½

2. Organisation structure& organisationalbehaviour 10 21 02 1 ½

3 Production Management 8 13 01 01

4. Materials Management 8 16 02 01

5. Marketing ,Sales &Feasibility study 8 13 01 01

6. Industrial legislation & safety 8 13 01 01

7. Introduction to ISO 9000& T.Q.M. 6 13 01 0

8. Role of Enterprenuerand EnterprenuerialDevelopment 8 13 01 01

Total 60 110 10 08

OBJECTIVESOn completion of the course the student will be able to

1.0 Understand the principles of management as applied toindustry.

1.1 Define industry, commerce (Trade) and business.

1.2 Know the need for management.

243

1.3 Understand the evolution of management

1.4 Explain the principles of scientific management.

1.5 Understand functions of Management.

1.6 Differentiate between management and administration.

2.0 Know types of ownerships, the organisation structure ofan industry and the behaviour of an individual in anorganisation.

2.1 Understand types of ownerships

2.2 Differentiate types of ownerships.

2.3 Understand salient features of joint stock companies.

2.4 Understand the philosophy and need of organisation structureof an industry.

2.5 Understand the line, staff and Functional organisations.

2.6 List the advantages and limitations of line, staff and functionalorganisations.

2.7 List different departments in a large scale industry.

2.8 Explain the factors of effective organisation.

2.9 Understand organisational behaviour.

2.10 Conduct for analysis.

2.11 Assess the incurring applicants.

2.12 Outline the selection process.

2.13 Understand the sources of manpower.

2.14 State motivation theories.

2.15 State Maslow's Hierarchy of needs.

2.16 List out different leadership models.

2.17 Explain the trait theory of leadership.

2.18 Explain behavioural theory of Leadership.

2.19 Explain the process of decision Making.

2.20 Outline the communication process.

244

3.0 Understand the different aspects of productionmanagement.

3.1 Differentiate and integrate production, planning and control.

3.2 Relate the production department with other departments.

3.3 State the need for planning and it's advantages.

3.4 Explain the stages of Production, planning and control.

3.5 Explain routing methods.

3.6 Explain scheduling methods.

3.7 Explain dispatching.

3.8 Draw PERT/CPM networks.

3.9 Identify the critical path.

4.0 Understand the role of materials management industries.4.1 Explain the role of the materials in Industry.

4.2 Derive expression for inventory control.

4.3 Explain ABC analysis.

4.4 Define safety stock.

4.5 Define reorder level.

4.6 Derive an expression for economic ordering quantity.

4.7 Explain stock layout.

4.8 List out stores records.

4.9 Explain the Bin card.

4.10 Describe Cardex method.

4.11 Explain purchasing procedures.

4.12 List out purchase records.

4.13 Describe the stores equipment

4.14 Understand marketing, sales and feasibility study.

4.15 Explain marketing functions.

4.16 Explain Sales function.

4.17 List out market conditions.

245

4.18 Differentiate Sellers and Buyers' market.

4.19 Differentiate monopoly, oligarchy, and perfect competition.

4.20 Conduct market and demand surveys.

4.21 Differentiate product and production analysis.

4.22 Identify the input materials, i.e. Bill of materials

4.23 Explain the concept of cost.

4.24 List out the elements of cost.

4.25 Explain the concept of contribution.

4.26 Explain break-even analysis.

4.27 Define the main policy requirements.

4.28 Decide the location.

4.29 Evaluate Economic and Technical factors.

4.30 Preparation of feasibility study.

4.31 List out different products currently in demand with market orindustry.

5.0 Comprehend the provisions of industrial legislation inIndia. & Safety procedures

5.1 Describe employer and employee relations.

5.2 Describe the mechanics of Trade Unions.

5.3 Describe mechanics of settlement of in outs.

5.4 Explain the significance of collective bargain.

5.5 List out Welfare activities.

5.6 List out subsidy schemes.

5.7 Explain the total welfare concept.

5.8 List out the rights and responsibilities of employees andemployers.

5.9 List out the salient features of Indian Factories Act.

5.10 Explain the importance of safety at Work place.

5.11 List out the important provisions related to safety.

246

5.12 Explain the significance and mechanics of safety education.

5.13 Explain hazard and accident.

5.14 List out different hazards in the Industry.

5.15 Explain the causes of accidents.

5.16 Explain the direct and indirect cost of accidents.

5.17 List out provisions of Indian Electricity Rules laid in the electricity

act1923.

6.0 Understand ISO 9000 & TQM.6.1 Understand the concept of quality.

6.2 Know the quality systems and elements of quality systems.

6.3 Know the principles of quality Assurance.

6.4 Know the Indian Standards on quality systems.

6.5 Know the evolution of ISO standards.

6.6 Discuss ISO standards and ISO 9000 series of qualitysystems.

6.7 State the constituents of ISO 9000 series of standards for qualitysystems.

6.8 State the outstanding features and drawbacks of ISO 9000series of standards.

6.9 List the beneficiaries of ISO 9000.

6.10 Understand 5-S principles and ZERO DEFECT.

7.0 Understand the role of entrepreneur in economicdevelopment and in improving the quality of life.

7.1 Outline the concepts of Entrepreneurship.

7.2 Define the word entrepreneur.

7.3 Determine the role of Entrepreneurship.

7.4 Describe the profile of an entrepreneur.

7.5 Explain the requirements of an entrepreneur.

7.6 Outline the expectations of Entrepreneurship.

247

7.7 Determine the role of entrepreneurs in promoting Small ScaleIndustries.

7.8 Describe the details of self-employment schemes.

7.9 Explain the importance of TS-IPASS.

7.10 List salient features of TS-IPASS.

7.11 Explain the method of product selection.

7.12 Explain the method of site selection.

7.13 Outline the method of plant layout.

7.14 List the financial assistance programmes.

7.15 List out the organisations that help an entrepreneur.

COURSE CONTENTS1. Principles and functions of management.

Definitions of Industry, Commerce and Business. Evolution ofmanagement theories. Principles of Scientific Management,functions of management. Difference of administration andmanagement.

2. Organisation Structure & organisational behaviour.

Role of industry, Types of ownership - Sole proprietorship,Partnership, Private limited, Public limited company, IndustrialCooperatives, Philosophy, types of Organisations, Line and Staffand functional organisations. Advantages and limitations,departments in a large scale industry. Effective organisation.Job analysis, Assessing applicants, selection, motivation,different theories, Leadership in organisation, decision making,communication,

3. Production Management.

Production, planning and control, relation with otherdepartments, need for planning and its advantages, Routing,scheduling, despatching, PERT and CPM, simple problems.

248

4. Materials Management.

Materials in industry, inventory control model, ABC Analysis,Safety stock, re-order, level, Economic ordering quantity, Storeslayout, stores equipment, Stores records, purchasingprocedures, purchase records, Bin card, Cardex.

5. Marketing, Sales & Feasibility Study

Sellers and Buyers markets, Marketing, Sales, Marketconditions, monopoly, oligarchy, perfect competition, PricingPolicies. Cost Elements of Cost, Contribution, Break evenanalysis, Market Survey, Product and production Analysis,Materials input, Manpower, Location, Economic and TechnicalEvaluation, preparation of Feasibility study reports, - differentproducts - Mechanical, Electrical, Electronics, consumer items,Consumer desires etc.

6. Industrial Legislation & safety.

Employer - Employee relations, Trade, Union Settlement ofdisputes, collective bargaining, Welfare activities, subsidies,Total Welfare concept, rights and responsibilities and Employersand employees. Salient features of Indian Factories Act,Important of Safety at work places, factories Act- Provisions,Safety Education, Hazards, causes of accidents, Cost ofaccidents, Indian Electricity rules.

7. Introduction to ISO 9000 and TQM.

Concept of quality discussed by B. Crosby W. Edward, Deming,Shigco Shingo.

Quality systems - Definitions of the terms used in qualitysystems like, quality policy, quality management, qualitysystems, quality control and quality assurance.

Elements quality systems : Management responsibility, Qualitysystem, contract review, design control, document control,purchasing, purchaser - supplied product, product identificationand traceability, process control, Inspection and testing.

249

Principles of quality assurance - Definition of quality assurance.

Indian standards on quality systems - Main features of IS 13999:1990, IS 14000 : 1990, IS 14004 : 1990, IS 14001: 1990, IS14002 : 1990, IS 14003: 1990.

Know the necessity of International standards - Evolution ofISO. 5-S principles - importance - meaning - approach - benefits

Various standards under ISO - Outstanding features of ISO9000 series of standards - ISO 9000 Phenomenon ISO 9000series of quality systems - Constituents of ISO 9000 series ofstandards for quality systems.

Drawbacks of ISO 9000 series of standards, list thebeneficiaries of ISO 9000 (Whom does ISO 9000 help).

8. Role of Entrepreneur & Entrepreneurial Development.

Concept, definition, role, expectation, entrepreneurship VsManagement, promotion of S.S.I. Self - employment schemes.The importance and salient features of TS-IPASS.

Product selection, site selection, plant layout, profile andrequirement, Institutional support needed, financial assistanceprogrammes.

REFERENCE BOOKS1. Industrial Engineering and Management -by O.P Khanna

2. Production Management- by Buffa.

3. Engineering Economics and Management Science - by Banga& Sharma.

4. S.S.I Hand Book by S.B.P. Publishers.

5. Personnel Management by Flippo.

6. Entrepreneurship - by NITTT&R, Chennai.

*****

250

WELDING TECHNOLOGYSubject Title : Welding TechnologySubject Code : MET-702(A)Periods per week : 05Total periods per semester: 75



(3 Marks) (10Marks)

1. Basic concepts ofWelding 10 13 1 1

2. Oxy-Acetylene welding 12 17 2 1

3. Shield arc welding 12 17 2 1

4. Gas shield Arc welding(Inert gas welding) 12 17 2 1

5. Special Weldingprocesses 15 23 1 2

6. Metallurgy of welds 8 13 1 1

7. Inspection and testing of welds 6 10 1 1

Total 75 110 10 08

OBJECTIVESUpon the completion of the course the student will be able to:

1.0 Basic concepts of Welding.1.1 State the various metal joining techniques.

1.2 Define welding.

1.3 Classify the welding processes - fusion and pressure weldingprocesses

1.4 List the important welding process

1.5 Know the importance of welding as a fabrication technique.

1.6 Know the important welding terms.

251

a. Weld bead b.Crater c. Filler weld d. Penetration

e. Puddle f.Weld metal g. Weld pass

1.7 Know the different types of weld joints .

a. Butt joint b.Lap joint c. Corner joint

d. T - joint e. Edge joint

1.8 Know about the welding position.

a. Flat b. Vertical c. Horizontal d. Overhead

1.9 Know the need for edge preparation in welding.

1.10 Mention the edge preparation Methods for butt joints.

a. V - type b. Bevel

c. U - type d. T - type

1.11 Know the safety practices in welding.

2.0 Oxy Acetylene welding.2.1 List the steps involved in burning of Oxygen and acetylene.

2.2 Know the characteristics of oxy acetylene flame.

2.3 Describe the types of oxy acetylene flames and state theirapplications.

a. Carburising

b. Oxidizing

c. Neutral

2.4 Mention the equipment for oxy acetylene welding.

2.5 Oxygen and acetylene cylinders

a. Regulators b. Torches

c. Hose pipes d. Control valves

2.6 Draw the sketch of oxyacetylene welding outfit and label theparts with colour codes.

2.7 Know the principles and operations of pressure reductionregulator, with line diagrams.

a. Single stage regulator

252

b. Two stage regulator

2.8 Explain the types of torches used in oxyacetylene welding withneat sketches.

a. Injector or low pressure torch

b. Equal pressure torch

2.9 Know the operation of a Oxyacetylene welding torch.

2.10 Know the precautions in storage of O2 & C2H cylinders

2.11 Explain the different welding techniques with neat sketches

a. Fore hand welding techniques

b. Back hand welding technique

2.12 Mention the advantages and applications of Oxyacetylenewelding .

3. Electric Arc welding.3.1 Define Arc Column

3.2 Explain arc column theory with typical Arc welding circuit.

3.3 Know what are the major heat areas in the arc column

3.4 Define arc blow

3.5 Its causes and effect on welding

3.6 Mention the Methods of reducing the arc blow

3.7 Know about straight and reverse polarity - DCSP and DCRPand differentiate.

3.8 Mention arc welding machines based on source of electricpower

a. AC welding machines

b. DC welding machines

3.9 Define welding crater.

3.10 Explain the metal transfer mechanism from electrode to thebase metal with line sketches

3.11 Know what burn off rate.

3.12 Define proper arc length

253

3.13 Mention the Methods of striking an arc

3.14State the advantages and applications of Arc Welding

3.15Explain the principle of submerged arc welding

3.16 List the advantages and applications of submerged arc welding

4. Gas shield arc welding.4.1 Introduction

4.2 List different inert gas welding processes.

(a) Tungsten inert gas welding (TIG) or GTAW.

(b) Metal inert gas welding (MIG processes

4.3 Know how heat is liberated in TIG & MIG processes.

4.4 Know the difference in penetration in TIG & MIG.

4.5 State the functions shielding gases.

4.6 Explain the metal transfer mechanism in MIG with line sketches.

4.8 Write down the types of electrodes used in TIG.

a) Tungsten b) Thoriated Tungsten

4.9 List the components of complete TIG & MIG out fits.

4.11 Explain the TIG welding technique.

4.12 Know how filler metal is added to the puddle

4.13 State the advantages and application of TIG

4.14 Explain the MIG welding technique

4.15 State the advantage and applications of MIG.

5.0 Special Welding processes.5.1 List the special welding processes

a. Plasma arc welding

b. Resistance welding

c. Electro slag welding

d. Electro beam welding and laser beam welding

e. Thermit welding

254

5.2 Define plasma arc welding

5.3 Differentiate plasma gas and shielding gases.

5.4 Explain the plasma arc welding process(in brief)

5.5 State application and advantages of plasma arc welding

5.6 Define resistance welding

5.7 List the types of resistance welding

A. Spot welding

B. Seam welding

C. Projection welding

D. Butt welding

E. Flash welding

5.8 Explain in brief the above resistancewelding processes andstate its applications

5.9 Define electro slag welding

5.10 Explain in brief the electro slag welding process

5.11 State its application

5.12 Define electron beam welding

5.13 Explain in brief the electron beam welding

5.14 State the application of electron beam welding

5.15 Define thermit welding

5.16 Explain in brief the thermit welding process

5.17 State the applications of thermit welding process

5.18 Define laser beam welding

5.19 Explain in brief the laser beam welding

5.14 State the application of laser beam welding

6.0 Metallurgy of welds6.1 Explain the metallurgical aspects of welding w.r.t weld puddle

solidification

6.2 Explain the different heat affected zones in welding.

255

6.3 Draw the microstructure of a cross section of a weld joint andstate the salient Features

6.4 Define weldability

6.5 Explain the factors influencing weldability of Metals and Alloys.

6.6 State the necessity of post weld treatment

6.7 Explain in brief the post weld treatments

7.0 Inspection and testing of welds7.1 Define strength of a weld

7.2 List the various welding defects and state their remedies

a) Under cut & overlap

b) Gas porosity

c) Slag inclusion

d) Poor penetration

e) Centre line cracking

7.3 List the inspection and testing Methods of welds

7.4 Mention the purpose of each test

COURSE CONTENTS

1.0 Basic concepts of Welding.: Def. and importance Types ofMetal joining techniques. Important Welding Terms. EdgePreparation and safety measures.

2.0 Oxyacetylene Welding: Introduction, Types andcharacteristics, Equipment used in oxy acetylene welding,pressure reduction regulators, Types of torches, differentwelding techniques, butt edge preparation, advantage andapplications.

3.0 Electric Arc welding : Introduction, Arc column theory, Arcblow, power supplies, Types of welding machines, Weldingcrater, burn off rate, Methods of striking an arc and Arc length,electrode movements, and applications, submerged arcwelding.

256

4.0 Gas shield arc welding (inert gas welding): Introduction,Types of processes - TIG & MIG. Mode of heat liberation. Typesof electrodes in TIG & MIG. Metal transfer mechanism,Advantages and application of TIG & MIG.

5.0 Other Welding processes: Introduction, List of special weldingprocesses, plasma Arc welding Resistance welding, Electroslag welding, electron beam welding, thermit welding and laserbeam welding.

6.0 Metallurgy of Welds: Introduction, metallurgical aspects ofwelding, weld ability, HAZ. Micro structures of welds. PWHT.

7.0 Inspection and testing of welds: Introduction, weldingdefects and remedies, Inspection and testing of welds.

REFERENCE BOOKS1. Welding and welding technology-by R.Little

2. Welding Engineering -by Agarwal&Tahilani

3. Welding Technology -by O.P.Khanna.

4. Manufacturing technology -by P.N.Rao

5. Engineering metallurgy part I & II-by Raymond A. Higgins.

*****

257

CORROSION ENGINEERINGSubject Title : Corrosion EngineeringSubject Code : MET-702BPeriods per week : 05Total periods per semester: 75



(3 Marks) (10Marks)

1 Introduction. 7 9 3 -

2 Corrosion Principles 16 23 1 2

3 Types of corrosion - I 14 23 1 2

4 Types of corrosion - II 14 23 1 2

5 Oxidation of Metals 12 16 2 1

6 Protection against corrosion 12 16 2 1

Total 75 110 10 08

OBJECTIVESUpon the Completion of course the students will be able tounderstand

1.0 Introduction to corrosion.

1.1 Define corrosion.

1.2 State the importance of corrosion study.

1.3 Classify corrosion.

1.4 State the equation for corrosion rate

2.0 Corrosion principles

2.1 Explain electro chemical principles of corrosion.

2.2 State Faraday's laws.

2.3 Explain types of electro chemical cells.

258

2.4 Explain thermodynamic principles of corrosion.

2.5 Explain electrode potential of Metals.

2.6 Derive Nernst equation for electrode potentials.

2.7 Explain reversible hydrogen electrode.

2.8 Briefly explain important reference electrodes.

2.9 State signs for electrode potentials.

2.10 Explain electromotive series/ standard electrode potentials andthermodynamics corrosion theory.

2.11 Explain galvanic series of Metals and alloys.

2.12 State the applications and limitations of the galvanic series.

2.13 Explain E/PH diagrams.

2.14 Limitations of E/PH diagrams.

3.0 Types of corrosion -I

3.1 Explain atmospheric corrosion.

3.2 State the factors effecting atmospheric corrosion.

3.3 State the remedial measures of atmospheric corrosion.

3.4 Explain corrosion by minerals and acids.

3.5 Explain Inter granular corrosion.

3.6 Explain sensitization in austenitic stainless steels.

3.7 Explain pitting corrosion and state general characteristics ofpitting corrosion.

3.8 Explain pitting in stainless steels and its prevention.

3.9 Explain about exfoliation.

3.10 State general characteristics of exfoliation and its remedialmeasures.

3.11 Briefly explain De alloying.

3.12 Briefly explain about De zincification.

259

3.13 Briefly explain about Graphitization.

3.14 Briefly explain about galvanic corrosion.

3.15 State the factors effecting galvanic corrosion and its protectivemeasures.

4.0 Types of corrosion - II

4.1 Explain Crevice corrosion.

4.2 State the factors effecting crevice corrosion and its remedialmeasures.

4.3 Explain fill form corrosion.

4.4 State the factors affecting fill form corrosion and its remedialmeasures.

4.5 Briefly explain about water lime attack.

4.6 Briefly explain metal -ion concentration cell corrosion.

4.7 Explain stress corrosion cracking.

4.8 State the factors affecting stress corrosion cracking and itsremedial measures.

4.9 Explain about Hydrogen embrittlement.

4.10 Briefly explain about corrosion fatigue.

4.11 Briefly explain about erosion corrosion.

4.12 Briefly explain cavitational corrosion.

4.13 Briefly explain fretting corrosion.

5.0 Oxidation of Metals.

5.1 Explain protective and non protective scales.

5.2 Explain electrochemical nature of oxidation.

5.3 Explain oxidation kinetics.

5.4 Explain Oxide structure.

5.5 State the effect of alloying on oxidation.

260

5.6 Explain Oxidation resistant alloys.

6.0 Protection against corrosion.

6.1 Explain design improvements.

6.2 Explain protection against corrosion by change of metalcomposition, microstucture and environment.

6.3 Explain uses of Inhibitors.

6.4 Explain protection against corrosion by change of operatingvariables.

6.5 Explain protection against corrosion by change of metalpotential.

6.6 Explain cathodic protection and anodic protection.

6.7 Compare between cathodic protection and anodic protection.

6.8 Explain metallic and non metallic coatings and list out the usesof coatings.

COURSE CONTENTS1.0 Introduction to Corrosion: Definition, Importance of corrosion

studies, Classification of corrosion Expression for corrosionrate.

2.0 Corrosion principles: Electo - chemical principles ofcorrosion, Faraday's laws, Types of electrochemical cells,Thermodynamic principles of corrosion, Electrode potential ofMetals, Nernst Equation for electrode potentials, ReversibleHydrogen electrode, Conversion of signs for electrode potentials,Electromotive series/standard electrode potentials andthermodynamic corrosion theory., Galvanic series of Metalsand alloys, Extended thermodynamics - E/PH diagram.

3.0 Types of Corrosion - I : Atmospheric corrosion, Corrosion bymineral acids, Intergranular corrosion, Sensitization in austeniticstainless steels - Mechanism, Pitting corrosion ,Exfoliation, Dealloying, Dezincification, Graphitization, Galvanic corrosion,

261

4.0 Types of Corrosion - II : Crevice corrosion, Fill form corrosion,Water line attack, Stress corrosion cracking, Hydrogenembrittlement, Corrosion fatigue, Erosion corrosion, Cavitationcorrosion, Fretting corrosion.

5.0 Oxidation of Metals: Protective and non protective scales,Electrochemical nature of oxidation, Oxidation kinetics, Oxidestructure, Effect of alloying, Oxidation Resistant alloys.

6.0 Protection against corrosion: Design improvement, Changeof metal, Change of composition, Change of microstructure,Change of environment, Use of inhibitors, Change of operatingvariability, Change of metal potential, Cathodic protection,Anodic protection, metallic coatings, Non metallic coatings.

REFERENCE BOOKS

1. An Introduction to metallic corrosion and its prevention- by RajNarayan. (Oxford & IBH Publishing Co)

2. Corrosion Engineering - by Greene & Fontana (Mc - GrawhillPublishing.)

*****

262

METAL CASTING TECHNOLOGYSubject Title : Metal Casting TechnologySubject Code : MET-703Periods per week : 05Total periods per semester: 75



(3 Marks) (10Marks)

1. The types of Cast Irons 5 3 1 -

2. Melting of Cast Irons 13 13 1 1

3. Grey Iron 14 16 2 1

4. Ductile Iron 10 13 1 1

5. Malleable Iron 7 13 1 1

6. Aluminium Foundrypractice 7 13 1 1

7. Copper FoundryPractice 7 13 1 1

8. Steel Foundry Practice 6 13 1 1

9 Cleaning & Salvage ofcastings 6 13 1 1

Total 75 110 10 08

OBJECTIVESOn the completion of the course the student will be able to:

1. Introduction to cast irons1.1 Define the terms cast iron, grey cast iron, white cast iron, chilled

cast iron, malleable iron , nodular iron and compacted grayIron

1.2 Express the composition of various cast irons

1.3 Define graphitisation.

1.4 State the factors effecting graphitisation.

263

1.5 Explain the solidification process of cast irons.

(a) Grey cast iron (b) White cast iron.

1.6 State the micro constituents present in cast irons.

2. Melting of cast irons2.1 State the advantages & limitations of cupola.

2.2 Describe the mechanical structure of cupola with a sketch.

2.3 Explain various steps in the operation of cupola.

2.4 Describe various zones with chemical reactions.

2.5 Explain the principles of cupola operation.

2.6 Explain the melt control tests

(a) Chill test (b) Spiral fluidity test.

2.7 Calculate the molten metal analysis from the given chargeanalysis.

2.8 State the advantages and disadvantages of Induction furnace.

2.9 List out different types of Induction furnaces.

2.10 State the principle of Induction melting.

2.11 Explain the melting practice of cast iron in induction furnace.

3. Grey iron3.1 State the properties and applications of Grey iron.

3.2 Classify the Grey irons.

3.3 State the effect of Silicon on the iron-iron carbide system.

3.4 Explain the chemical composition requirements of Grey iron.

3.5 Explain the solidification of Grey iron w.r.t Graphitisation.

3.6 List out the moulding methods used in Grey iron foundry.

3.7 Describe the additives required for ease of moulding.

3.8 State the foundry properties of Grey iron.

3.9 Calculate the pouring temperature and fluidity for a givencomposition of grey iron.

3.10 State different heat treatments of Grey iron.

264

3.11 Explain the effect of alloying elements on the properties andstructure of grey iron.

4. Ductile iron4.1 State the properties and uses of ductile iron.

4.2 Explain the composition requirements for ductile iron.

4.3 State the role of Mg.

4.4 Explain various Magnesium treatment methods.

4.5 Describe the metallurgical process control-

4.6 Fading of Mg. (b) Nodule size and count. (c) Carbide formation.

4.7 State the inoculation process.

4.8 State different heat treatments of ductile iron.

4.9 Draw the microstructure & identify the phases of ductile iron.

5. Malleable iron5.1 State the properties & uses of malleable iron.

5.2 Mention the composition of white iron.

5.3 Draw the microstructure & identify of phases of white iron.

5.4 Explain the malleabilisation treatment of white iron for theproduction of malleable iron with referance to microstructuralchanges

5.5 List out the types of malleable iron.

5.6 Draw the microstructure of white & black heart malleable iron.

5.7 List the methods of producing black heart malleable iron.

5.8 Explain the method of producing black heart malleable iron

6. Aluminium foundry practice6.1 List the uses of Aluminium castings.

6.2 State the different moulding methods used in an aluminiumfoundry.

6.3 Explain the melting procedure of aluminium alloys with respectto drossing, gas absorption, fluxing and flushing, grain refiningand pouring temperature.

265

6.4 state suitable Gating ratios for aluminium alloys.

6.5 State the methods of Gating & Risering of aluminium alloys.

6.6 State the importance of Multiple-ingating.

6.7 State effect of unpressurised gating systems for aluminiumcastings

6.8 Explain the different casting defects in aluminium castings withremedial measures

7. Copper alloy foundry practice

7.1 State the uses of copper alloy castings.

7.2 state the moulding procedures used in a copper alloy foundry

7.3 Explain the melting procedure of copper alloys with respect todrossing, oxygen and Hydrogen in copper melting, reaction ofimpurities, de-oxidation, control of gases and temperaturecontrol.

7.4 State the design of gating & risering system in the case ofcopper alloy casting

7.5 Define the term reverse shrinkage

7.6 Explain the different casting defects in copper castings withremedial measures

8. Steel foundry practice8.1 State the moulding processes used in steel foundry.

8.2 State the importance of Zircon sands.

8.3 State the importance of mould coating in steel foundry

8.4 State the effects of fluidity and shrinkage in the design of gates

8.5 State the purpose of a riser.

8.6 Give the effective feeding distance of a riser.

8.7 Explain the defects caused due to cores.

(a) Hot tear formation (b) metal penetration.

9. Cleaning of casting9.1 List out the various cleaning operations.

266

9.2 Explain different techniques employed in removal of gates,risers.

9.3 Explain the various surface cleaning operations.

9.4 Differentiate between Tumbling & Blasting.

9.5 Describe the Trimming operations.

9.6 Mention the Finishing operations.

9.7 Define the term Salvage of castings.

9.8 List out various Salvage Techniques.

9.9 State different inspection methods

COURSE CONTENTS

1. Introduction to Cast irons: Definition of Cast Iron - Types ofCast irons, Graphitisation, factors effecting, Solidification of castirons-GI, W.I, and Micro constituents.

2. Melting of Cast irons: Introduction, Cupola - Advantages &limitations, Mechanical structure, Steps in operation, Principlesof cupola operation; melt control tests, induction melting,advantages & disadvantages, types, principle, operation.

3. Grey Iron: Introduction,properties, uses, classification, Fe-C-Si system, chemical composition requirements, solidificationw.r.t Graphitisation, method of moulding, additives, Gating &Feeding, foundry properties, heat treatment, alloy grey iron.

4. Ductile Iron: Introduction, properties & uses, chemicalcomposition requirements, role of Mg, Mg treatment methods,inoculation, metallurgical process control, heat treatment.

5. Malleable Iron: Introduction, Properties & uses, compositionof white iron, malleabilisation treatment, micro structures,methods of black heart malleable iron production.

6. Aluminium foundry practice: Introduction, properties & uses,melting procedure, moulding, gating and risering.

7. Copper alloy foundry practice: Introduction, properties &uses, moulding, melting procedure, gating and risering.

267

8. Steel Foundry Practices: Introduction, moulding, zirconsands, gating and risering, common defects due to cores.

9. Cleaning of casting: Introduction, Cleaning operations,Salvage of casting, inspection.

TEXT BOOKS1. PRINCIPLE OF METAL CASTING by HEINE AND ROSENTAL

REFERENCE BOOKS1. FOUNDRY TECHNOLOGY by P.L. JAIN

2. Foundry technology by M.Lal, Khanna Publications.

3. Foundry technology by N.SRINIVAS.

*****

268

MECHANICAL METALLURGYSubject Title : Mechanical MetallurgySubject Code : MET-704Periods per week : 05Total periods per semester: 75



(3 Marks) (10Marks)

1 Plastic deformation ofMetals 15 29 3 2

2 Strengthening Mechanisms 10 13 1 1

3 Mechanical workingof Metals 10 13 1 1

4 Rolling 10 16 2 1

5 Extrusion 10 13 1 1

6 Forging 10 13 1 1

7 Sheet metalforming processes 10 13 1 1

Total 75 110 10 08


1. Plastic deformation of Metals1.1 Define elastic and plastic deformation

1.2 Define Lattice Defect.

1.3 Classify Lattice defects.

1.4 Define

a. Point Defect

b. Vacancy

269

c. Substitutional impurity

d. Interstitial impurity

1.7 Give the relation between number of vacancies andtemperature

1.8 Define dislocation.

1.9 Define edge and screw dislocation.

1.10 Explain Edge Dislocation and Screw dislocation.

1.11 Know burgers vector and burgers circuit.

1.12 Define slip and slip system.

1.13 List the slip systems for F.C.C., B.C.C. & H.C.P. crystals.

1.14 Explain Slip with both Edge & Screw Dislocations.

1.15 Explain Dislocation climb & Cross slip.

1.16 Differentiate Edge & Screw Dislocations.

1.17 Define Critical Resolved Shear Stress (C.R.S.S).

1.18 Derive C.R.S.S for a single crystal.

1.19 Numerical problem on CRSS

1.20 Explain the low angle grain boundaries, stacking faults.

1.21 Explain Twinning.

1.22 Differentiate annealed & mechanical twins.

1.23 Identify twin planes of B.C.C., F.C.C and H.C.P.

1.24 Compare Slip and Twinning.

1.25 Define Jog & sessile dislocations.

1.26 Know the Bauschinger effect.

2. Strengthening Mechanism.2.1 List different Strengthening mechanisms.

2.1 Explain strain hardening of a F.C.C. single crystal.

2.3 Explain Solid Solution Strengthening.

2.4 Explain Grain Boundary Strengthening.

2.5 Explain Precipitation Hardening.

270

2.6 Explain Dispersion Hardening.

2.7 Explain Yield point phenomenon & Strain Ageing.

3. Mechanical Working of Metals.3.1 Define Mechanical working of Metals

3.2 Define hot working & Cold working.

3.3 List out the advantages and disadvantages of hot working andcold working.

3.4 Know the Necessity of annealing to cold worked metal.

3.5 State various stages in annealing.

3.6 Explain recovery, re-crystallization and grain growth.

3.7 Define the re-crystallization temperature.

3.8 Explain the variables influencing the re-crystallizationtemperature.

4. Rolling4.1 Define Rolling.

4.2 Explain the rolling process.

4.3 Generalize the forces and geometrical relationships involvedin rolling

4.4 Derive the Limiting Condition for Rolling (prove = tan ).

4.5 Derive the Expression for Maximum Reduction in Rolling.

4.6 Numerical problems on maximum reduction in rolling

4.7 Summarize the main variables in rolling.

4.8 Classify the rolling mills with respect to number of rolls in eachstand and the types of products to be manufactured.

4.9 List the different shapes and types of grooves.

4.10 Explain various types of rolling defects and their remedies.

5. Extrusion5.1 Define Extrusion

5.2 Classify the extrusion processes.

5.3 Differentiate the direct and indirect extrusion processes.

271

5.4 List the extrusion equipment.

5.5 Discuss the variables in extrusion processes.

5.6 Explain the extrusion of tubes.

5.7 Know the extrusion defects and their remedies.

5.8 Explain the production of seamless pipes.

5.9 Discuss about wire drawing process.

6 Forging6.1 Define Forging.

6.2 Classify the forging operations.

6.3 Explain the open-die forging operations of Edging, Fullering,Swaging, Drawing down, Punching & Piercing.

6.4 Specify the importance of rotary swaging.

6.5 State the principles underlying the upset forging.

6.6 Explain the process of manufacture of bolt head.

6.7 Explain the cold heading process for manufacture of Nails.

6.8 Explain in detail the closed - die forging operation.

6.9 Know the various forging defects and their remedies.

7. Sheet Metal Forming7.1 Explain Rubber forming operation and its importance.

7.2 Explain the spinning process.

7.3 Explain the Roll forming process.

7.4 Explain the shearing and blanking processes.

7.5 Explain the bending operations.

7.6 Explain stretch forming process.

7.7 Explain the uses of deep drawing process and its importance.

7.8 Discuss the deep drawing process.

7.9 Discuss the various deep drawn product defects - orange peeleffect, stretcher strains, earing and their remedy.

7.10 Explain the re-drawing process

272

COURSE CONTENTS1.0 Plastic deformation of Metals : Elastic and plastic

deformation of metals, Lattice Defects, Slip and Slip system,Slip systems for F.C.C., B.C.C. & H.C.P. crystals, DislocationClimb & Cross slip, Critical Resolved Shear Stress, Low anglegrain boundaries, stacking faults, Twinning, Twin planes ofB.C.C., F.C.C and H.C.P., Jog & sessile dislocation,Bauschinger effect.

2.0 Strengthening Mechanisms: Strain hardening of a F.C.C.single crystal, Solid Solution Strengthening, Grain BoundaryStrengthening, Precipitation Hardening, Dispersion Hardening,Yield point phenomenon & Strain Ageing.

3.0 Mechanical working of Metals: Hot working & Cold working,Necessity of annealing to cold worked metal, Recovery, Re-crystallization and Grain Growth, Re-crystallizationTemperature, Variables influencing the re-crystallization.

4.0 Rolling : Rolling Process, Forces and geometricalrelationships involved in rolling, Limiting Condition for Rolling (= tan ), Maximum Reduction in Rolling, Variables in rolling,Classification of rolling mills, different shapes and types ofgrooves, Rolling defects and their remedies.

5.0 Extrusion : Extrusion, Direct and Indirect extrusion process,extrusion equipment, variables in extrusion process, Extrusionof tubes, Extrusion defects and their remedies, Production ofseamless pipes, Wire drawing process.

6.0 Forging: Forging, Open die forging operations Edging,Filleting, Swaging, Drawing down, Punching & Piercing, Rotaryswaging. Principles of upset forging, Process of manufactureof bolt head, cold heading process for the manufacture of Nails,closed - die forging operations, forging defects and theirremedies.

7.0 Sheet Metal Forming : Rubber forming, spinning, Roll formingprocess, shearing and blanking, bending operations, stretch

273

forming, uses of deep drawing process and their importance,deep drawing process, deep drawn product defects - orangepeel effect, stretcher strains, earing and their remedy, re-drawing process.

TEXT BOOKS1. Mechanical metallurgy - by G.E. Dieter.

REFERENCE BOOKS2. Engineering metallurgy Volume - II - by Higgins.

3. Manufacture of Iron and Steel Volume - IV - by Bash forth.

4. Introduction to Powder metallurgy - by A.K Sinha.

*****

274

NON - FERROUS EXTRACTIVE METALLURGYSubject Title : Non - Ferrous Extractive

MetallurgySubject Code : MET-705Periods per week : 05Total periods per semester: 75



(3 Marks) (10Marks)

1. Copper Extraction 19 16 2 1

2. Aluminium Extraction 16 16 2 1

3. Zinc Extraction 8 13 1 1

4. Lead Extraction 8 13 1 1

5. Magnesium Extraction 6 13 1 1

6. Titanium Extraction 6 13 1 1

7. Zirconium Extraction 6 13 1 1

8. Thorium Extraction 6 13 1 1

Total 75 110 10 08

OBJECTIVESAfter the completion of the course the students will be able to:

1.0 Copper extraction1.1 List the properties1.2 State the effect of impurities on properties.1.3 Appreciate the uses.1.4 Classify the ores.1.5 State the native ores, oxide ores, and sulphide ores.1.6 Give the chemical composition of the ore.1.8 State the extraction techniques of copper.1.9 State the important steps in the pyrometallurgical extraction of

copper.

275

1.8 Explain roasting process.

1.9 Explain the smelting of oxide &sulphide ores.

1.11 Explain the reverberatory smelting, flash smelting.

1.12 State the advantages of Flash smelting over reverberatorysmelting

1.13 Define converting.

1.14 State the purpose of converting.

1.15 Explain the two stages of converting with chemical reactions.

1.16 State the advantages of side blown converter.

1.17 Explain fire refining operation.

1.18 Explain electrolytic refining- multiple systems & series systems.

1.10 Explain hydrometallurgical extraction of copper with flow sheet

1.21 Explain the recovery of precious Metals with flow sheet

1.22 State the recent extraction techniques in copper extraction

2.0 Aluminum extraction2.1 State the properties and applications of aluminium

2.2 State the different ores with chemical composition.

2.5 State the steps in the extraction of aluminium.

2.6 Explain purification of bauxite by Bayer process

2.7 Understand the factors effecting Bayer process

2.8 State the reasons for the unfeasibility of carbothermic reductionof alumina

2.9 State the role of Cryolite in the electrolytic reduction of alumina.

2.10 Explain the construction &operation of reduction cell.

2.11 Explain factors effecting Hall-Heroult process.

2.12 Define Anode effect.

2.13 State the causes & remedies of anode effect.

2.14 Know the necessity of refining Aluminium.

2.15 Explain the Hoope's process.

276

2.16 Explain the Gadau process of refining.

2.17 Define anodizing.

3.0 Zinc extraction3.1 List the properties and uses of zinc.

3.3 Know the ores & their chemical composition.

3.6 List the extraction Methods & techniques.

3.7 Explain pyrometallurigical extraction.

3.8 Explain roasting.

3.9 State the purpose of roasting.

3.10 Define distillation.

3.11 Explain the horizontal retort process.

3.12 Explain the vertical retort process.

3.13 Distinguish between vertical retort and horizontal retort process.

3.13 Explain the electrothermic production of zinc.

3.14 Explain the blast furnace method of production of zinc (ImperialSmelting Process)

3.15 Explain the hydrometallurgical techniques for the production ofzinc with flowsheet.

3.16 Understand galvanizing.

4.0 Lead extraction4.1 List the properties & uses.

4.2 State the ores & their chemical composition.

4.5 Explain the sinter - Roasting of lead ores with chemistry

4.6 Explain the smelting process in blast furnace.

4.7 Understand the chemistry.

4.8 Know the products.

4.9 Explain the treatment of base bullion.

4.10 Define drossing.

4.11 Define cupellation.

277

4.12 Explain the parke's process of desilversation of lead.

5.0 Magnesium extraction5.1 List the properties & uses

5.2 Name the ores & their chemical composition.

5.3 List the deposits in India.

5.4 List the extraction plants of Mg in India

5.5 Know the extraction techniques.

5.6 Explain the Dow's process of 'Mg' extraction.

5.7 Explain the pidgeon process.

6.0 Titanium extraction6.1 State the properties and applications of titanium.

6.2 Name the ores & chemical composition.

6.3 Understand the metallothermic reduction of halides.

6.4 Know the treatment of illuminate for up gradation.

6.5 Explain the chlorination of titanium oxide.

6.6 Explain the production of titanium by reduction of titaniumtetrachloride (krolls process).

6.7 State the advantages of Mg-Na alloy reduction over Mg reduction

6.8 Explain melting of titanium sponge.

6.9 Explain the purification of titanium by Vanarkell's iodide process.

6.10 List the recent extraction techniques in the extraction of titanium

7.0 Zirconium extraction7.1 State the properties of zirconium.

7.2 Know the applications of zirconium.

7.3 Name the ores of zirconium.

7.4 Understand the treatment of zircon.

7.5 Mention the Methods of separating the hafnium from zirconium.

7.6 Know the solvent extraction, fractional crystallization Methods.

7.7 Explain the production of pure zirconium oxide with flow sheet

278

7.8 Explain the production of zirconium sponge with flow sheet

7.9 Explain the production of mill products from sponge metal witha flow sheet

7.10 Know the production of zirconium powder.

7.11 Draw the flow diagram for the production of zirconium metalpowder.

8.0 Thorium extraction.

8.1 State the properties.

8.2 State the applications of thorium.

8.3 List the ores & deposits of thorium in India.

8.4 Explain treatment of Monazite sands (alkali leaching).

8.5 Distinguish between Acid leaching and alkali leaching of Monazite

8.6 Understand the Methods of production of Thorium metal.

8.7 Draw the flow sheet for the production of reactor grade thoriumnitrate.

COURSE CONTENTS:1.0 Copper Extraction Properties, uses, ores, roasting, pyro

metallurgical Extraction, reveberatory smelting, Flash smelting,converting, Fire refining, Electrolytic refining, Recovery ofprecious Metals, Hydrometallurgy of copper.

2.0 Aluminum Extraction Properties, uses, ores, Bayer process,Hall Heroult's process, refining of Aluminum, Hoope's process,Geadau process, Anodizing process

3.0 Zinc Extraction: Properties uses, ores, Extraction Methods,Roasting, distillation, Pyro metallurgical Extraction, HorizontalRetort, Vertical Retort process, Electro thermic reduction,Imperial smelting process, Hydro metallurgy; Galvanizing.

4.0 Lead Extraction: Properties, uses, ores,roasting, sintering,smelting in Blast Furnace, Treatment of base bullion, Refiningof lead, Parke's process of desilverisation.

279

5.0 Magnesium Extraction Properties, uses, ores, deposits,Pidgeon process, Dow process.

6.0 Titanium extraction Properties, Applications, ores, deposits,metallothermic reduction, Treatment of Ilmenite, chlorination,kroll's process, Vanarkell's process.

7.0 Zirconium Extraction; Properties, Uses, ores, Treatment ofZircon, Solvent extraction, Fractional crystallization, productionof pure zirconium oxide, Zirconium sponge, Zircalloy -2 Tubes,Zirconium Metal powder.

8.0 Thorium Extraction; Properties, Uses, Ores, Treatment ofMonazite sands, Alkali Leaching, Methods of Thorium Metalproduction, production of reactor grade thorium nitrate

REFERENCE BOOKS

1. Non-ferrous Extractive metallurgy - by Ray, Abraham & Sridhar

2. Non-ferrous extractive metallurgy - by Dennis

3. Elements of metallurgy - by Dr. Swaroop

4. Metal News - Magazine - for Economic & Status by I.I.M.

*****

280

MATERIAL TESTING LAB PRACTICE - IISubject Title : Material Testing Lab Practice - IISubject Code : MET-706Periods per week : 03Total periods per semester: 75

TIME SCHEDULES.No. Experiment No. Of Periods1. Liquid Penetrant Test 9

2. Magnetic Particle TestLongitudinal Crack Detection 9

3. Magnetic Particle TestTransverse Crack Detection 9

4. Ultrasonic TestCalibration of Equipment withV- block 9

5. Ultrasonic TestDetection of Flaws usingstandard Blocks 9

Total Periods 45

OBJECTIVESOn the completion of course a student should be able to:

1. Know how to conduct the liquid penetrant test to locate thesurface cracks on the given Material.

2. Detect longitudinal surface and sub surface defects in the givenmaterials by magnetic particle test.

3. Detect transverse surface and sub surface defects in the givenmaterials by magnetic particle test.

4. Calibrate the ultrasonic flaw detector using IIW-block andmeasure the thickness of given sample.

5. Detect the flaws in metallic objects using ultrasonic flawdetector.

281

Key competenciesExercise

Liquid Penetrant test

Magnetic Particle Test(Longitudinal CrackDetection)

Magnetic Particle Test(Transverse CrackDetection)

Ultrasonic Test(Calibration of equipment)

Ultrasonic Test(Flaws detection)

Key competencies expected

1. Prepare the sample for the test2. Identify the chemicals used3. Distinguish the chemicals employed4. Identify the cracks and interpret the result.5. Know the industrial applications.

1. Prepare the equipment with relevantconnections.

2. Prepare the sample for the test3. Identify the material suitability for the test4. Self Handling of the Equipment5. Identify the magnetic media for the test6. Set the equipment for longitudinal

magnetization7. Identifying the cracks8. Know the industrial applications

1. Prepare the sample for the test2. Identify the material suitability for the test3. Self Handling of the Equipment4. Set the equipment for transverse

magnetization.5. Identifying the cracks6. Know the industrial applications

1. Recognise the IIW test block2. Prepare the equipment with relevant

connections3. Identify the probes for the test4. Knowing the connections for the equipment5. Fixing the different settings for calibration

of the equipment.6. Measure the thickness of the object.7. Know the industrial applications

1. Identify the flaws and interpret the results.2. Know the industrial applications

282

COURSE CONTENT1. Determination of surface cracks by liquid penetrant test.

2. Identification of surface and sub-surface cracks by magneticparticle test i) longitudinal method ii) Transverse method.

3. Calibration of ultrasonic flaw detector using IIW test block andmeasure the thickness of given sample.

4. Identification of flaws by ultrasonic flaw detector.

*****

283

METAL CASTING LAB PRACTICESubject Title : Metal casting Lab practiceSubject Code : Met - 707Total No. of Periods : 03Total Periods Per Semester: 45

TIME SCHEDULESl.No. Experiment Title No. of periods1 Cupola furnace 15

2 Pit fired furnace 09

3 Oil fired furnace 09

4 Cleaning of castings 06

5 Casting defects 06

Total periods 45


1.0 Operation of cupola for melting of cast iron1.1 Know the uses of cupola in foundry

1.2 Identify the various parts of cupola furnace

1.3 Know the sequence of operations

1.4 Calculate the burden

1.5 Melting of cast iron

2.0 Prepare cast iron castings and conduct chill test2.1 Prepare the green sand mould

2.2 Conduct chill test

2.3 Pouring of molten metal in to mould

3.0 Analyse the casting defects and cleaning of castings3.1 Removal of casting from the mould

284

3.2 Removal of gates and risers

3.3 Observe the casting defects like blow holes, pin holes etc.

3.4 Analyse the reasons for casting defects

4.0 Operation of pit furnace for melting of aluminium, copperand its alloys

4.1 Parts of the pit furnace

4.2 Know the melting points of aluminium and copper alloys

4.3 Know the raw material composition

4.4 Reduce of dross formation

5.0 Operation of oil fired furnace for melting of aluminium,copper and its alloys

5.1 Parts of oil fired furnace

5.2 Know the charging sequence

5.3 Maintaining of furnace temperature

5.4 Melting of charge material

6.0 Use of fluxes in melting of aluminium and copper alloys 6.1 Define flux and purpose of flux

6.2 Types of fluxes used in melting aluminium and copper alloys

6.3 Know the composition of fluxes

7.0 Analyse the casting defects in aluminium and copperalloys

7.1 Types of defects occur in non ferrous castings

7.2 Method of analysis of casting defects

7.3 Classification of defects

Title of the experiment Key competency1.Cupola furnace 1. Calculate the burden for the given

raw material

2. Operation of cupola

3. Maintenance of proper coke bedheight

285

2.Pit fired furnace 1. Preparation of furnace area

2. Charging sequence of rawmaterial

3. Operation of furnace

3.Oil fired furnace 1.Charging sequence of rawmaterial

2. Parts of the furnace

3. Melting of charge material

4.Cleaning of castings 1. Removal of molding sand

2. Removal of gates and risers

5.Casting defects 1. Visual examination of castings

2. Identification of casting defects

3. Salvage or discard the casting

COURSE CONTENT1. Operation of cupola for melting of cast iron

2. Prepare cast iron castings and conduct chill test

3. Analyse the casting defects and cleaning of castings

4. Operation of pit furnace for melting of aluminium, copper andits alloys

5. Operation of oil fired furnace for melting of aluminium, copperand its alloys

6. Use of fluxes in melting of aluminium and copper alloys

7. Analyse the casting defects in aluminium and copper alloy.

*****

286

CAD LAB PRACTICESubject Title : CAD Lab PracticeSubject Code : MET-708Periods per week : 03Period per semester: 45

TIME SCHEDULESl No. Major Topics No. of periods1. Introduction to CAD 1.5

2. Selecting commands & Workingwith drawing 1.5

3. Viewing drawing and Workingwith coordinates 01

4 Creating simple entities by using draw commands 06

5. Modifying entities 06

6 Getting Drawing information 02

7. Working with text and practice 03

8. Dimensioning drawing and practice 03

9. 2D Drawing practice 12

10 Layers 03

11 Isometric views 03

12 Working with blocks 03

TOTAL 45

OBJECTIVESUpon completion of the course the student shall be able toUnderstand about the Computer Aided Drafting and its software

• Define Computer Aided Drafting

• List the Advantages of CAD and also various CAD software's

287

• Explain the importance of CAD software

• Explain the features of Graphic Work station

• Explain CAD Screen, Various tool bars and menus.

• Explain the benefits of Templates

• Use appropriate selection commands

• Practice commands using toolbars, menus, command bar

• Practise repeating a command, Nesting a command andmodifying a command

• Use prompt history window and scripts

• Practice mouse shortcuts

• Practice the Creating the drawing, saving the drawing with .dwgextension and Opening existing drawing

• Practice the setting up a drawing with drawing limits and drawingunits.

• Practice the setting and changing the grid and snappingalignment

• Practice the Entity snaps

• Use viewing tools of CAD

• Practice the use of Scroll bar, pan command and rotating viewto move around within drawing

• Practice the changing of magnification of drawing

• Use coordinate systems of the drawing

• Practice how the coordinate system work and it is displayed

• Practice the Find tool to determine the coordinates of a point

• Practice the Two dimensional coordinates such as AbsoluteCartesian, Relative Cartesian , Polar coordinates and directmethod to draw a line.

• Explain importance and use of Osnap/ Esnap points.

• Practice to draw with other drawing commands like circle,polygon and other.

288

• Create the simple and complex entities

• Draw the lines, circles, arcs, ellipses, elliptical arcs, rays andinfinite lines and shapes like Rectangles, Polygons, Polylines,Splines, donuts

• Practice the adding of hatch with required pattern and adjustingline angle and line space..

• Use the modifying tools to modify the properties of entities

• Practice the various methods of entity selection like window,cross window, fence, last and previous methods anddeselection method

• Practice the Deletion , breaking and trimming of entities

• Practice the Copying of entities within a drawing, betweendrawings

• Practice the Chamfering and Filleting of entities

• Practice the making of parallel copies, Mirroring entities andArraying entities

• Practice the Rearranging of entities by Moving, Rotating andReordering

• Practice the Resizing of entities by Stretching, Scaling,Extending.

• Practice the Editing of polylines: Opening, Closing, Curving,Decurving, Joining, Changing width and editing vertices

• Practice the Exploding of entities

• Use the drawing information retrieving tools Measure, Divide,Calculate, Display, and Track

• Divide the entities in to required number of segments

• Calculate the areas defined by points, of closed entities, andCombined entities

• Calculate the distance between the entities

• Calculate the angle between the entities

• Display the information about the entities and drawing status

289

• Track time spent working on a drawing

• Use the Text tool to create and formatting the various types oftext fonts and its styles

• Practice the creating, naming and modifying the text fonts

• Practice the Creation of line text, paragraph text

• Practice the Setting of line text style and its alignment

• Practice the Setting of Paragraph text style and its alignment

• Practice the Changing of line text and Paragraph text

• Practice the use of alternate text editor

• Use Dimensioning concepts to create dimensions, Editdimensions,

• Control dimension styles & variables and Adding geometrictolerances

• Practice the creating of linear, Angular, Diametral, Radial,Ordinate dimensions

• Practice the creating leaders and annotations

• Practice the making dimensions oblique,

• Edit the dimension text

• Practice the Controlling of dimension properties like arrowtypes, size, dim line adjustment, dim offset, text size , primaryand secondary units and format

• Practice the Controlling of dimension units, and dimensiontolerance

• Create 2D Drawings

• Create 2D drawings of standard mechanical components

• Organize the information on layers

• Explain the need and importance of Layers.

• Practice creating new layer, naming the layer and assigningproperties like Layer colour, Line type and line weight and settingthe current layer

290

• Practice the locking and unlocking of layers

• Practice the Freezing and thawing of layers

• Practice the layer visibility and layer printing

• Practice the loading of additional line types

• Create Isometric Views

• Practice setting the screen to Isometric mode

• Practice identification of iso top, iso left and iso right plane.

• Practice drawing in different iso planes with line andcircle(ellipse)

• Create Isometric views of simple objects

• Use the Blocks, Attributes and External references to managethe Drawing

• Define a block

• Explain the purpose of a block

• Practice the creating a block

• Practice the inserting a block

• Practice the redefining a block

• Practice the exploding a block

• Define an Attribute

• Practice the editing attribute definitions

• Practice the attaching attribute to blocks

• Edit attributes attached to blocks

• Extract attributes information

• Define external reference

• Practice the Attaching, Removing, and Reloading of externalreferences

• Practice the Binding, Clipping and changing the path of externalreferences.

*****

291

KEY competencies to be achieved by the studentNo. Experiment Title

1. Introduction to CAD

2. Selecting commands &Working with drawing

3. Viewing drawing

4. Working withcoordinates

5. Creating simple andcomplex entities

6. Getting Drawinginformation

Key components

• Open/close Autocad program• Understands Autocad Graphic

User• Interface(GUI) and various

toolbars

• Use prompt history window andscripts

• Practice the setting up a drawing• Practice the Entity

• Use Scroll bar, pan command,and rotating view

• to move around within drawing• Control visual elements like Fill,

Text, Blips and Line weight

• Use Two dimensional coordi-nates and Three

• dimensional coordinates• Use right-hand rule• Use filters in two and three

dimensions• Define user coordinate system

• Draw the simple shapes likelines, circles, arcs and complexshapes like polygons, planesetc.,

• Practice the adding of hatchpattern

• Measure the intervals anddistance between entities

• Divide the entities in to segments

292

• Calculate the areas defined bypoints, of closed entities, andCombined entities

• Create linear, angular, diametral,radial, ordinate

• Ordinate dimension• Practice the making dimension

oblique.

• Use proper 2D commands tocreate 2D drawings

• Use Iso snap command tocreate Isometric views

• Create , insert and explode ablock

• Attach attribute to blocks• Edit and extract attributes

attached to blocks

9. Dimensioning drawing

10. 2D Drawings

12. Isometric Views

13. Working with blocks

293

METALLOGRAPHY LAB PRACTICE-IISubject Code : MET - 709Total No. of Periods : 06Total Periods Per Semester: 90

TIME SCHEDULES.No. Experiment Title No. of periods1 Study of Microstructures of

stainless steel. 21

2 Study of Microstructures of copperand copper alloys 21

3 Study of Microstructures ofAluminium alloys 21

4 Study of Microstructures ofCase hardened steels 21

5 Study of Microstructures ofWeld steels 06

TOTAL 90OBJECTIVES

Up on Completion of the course the student shall be able to:1.0 Microstructures of stainless steel.1.1 Identify the phases present in Austenitic stainless steel1.2 Identify the phases present in Ferritic stainless steel.1.3 Identify the phases present in precipitation hardening steels.2.0 Microstructures of Copper and Copper alloys.2.1 Identify the phases present in pure copper2.2 Identify the phases present in Muntz metal (alpha plus beta)2.3 Identify the phases present in Aluminum Brass.2.4 Identify the phases present in Monel.2.5 Identify the phases present in Gun metal. 3.0 Study of Microstructures of Aluminium alloys.3.1 Identify the phases present in Duralumin3.2 Identify the phases present in Al-Si alloy

294

3.3 Identify the phases present in Al-Mg-Zn alloy 4.0 Study of Microstructures of Case hardened steels.4.1 Identify the phases present in Carburised steel.4.2 Identify the phases present in Nitrating steel.4.3 Identify the phases present in surface hardened steel.5.0 Study of Microstructures of Weld steels.5.1 Observation of heat affected zone in weld sample.5.2 Identify the phases present in case and core parts of weld

sample.

Title of the experiment

Microstructures of StainlessSteels

Microstructures of Copperand Copper alloys.

Microstructures of Aluminiumand Aluminium alloys.

Microstructures of CaseHardened Steels

Microstructures of Weldsteels.

Key competency

1. Identifying the phases inmicrostructures of different types ofStainless Steels

1. Identifying the phases inmicrostructures of different types ofCopper and Copper alloys.

1. Identifying the phases inmicrostructures of different types ofAluminium and Aluminium alloys.

1. Identifying the phases inmicrostructures of different types ofCase Hardened Steels

1. Identifying the phases inmicrostructures of different Weldsteels.

COURSE CONTENT1. Identification of Phases present in Austenitic, Feeritic and

Precipitation hardening steels.2. Identification of Phases present in Copper and copper alloys3. Identification of Phases present in Aluminium and Aluminium

alloys.4. Identification of Phases present in Case hardened steels5. Identification of Phases present in Weld steels.

*****

295

PROJECT WORK AND VIVA VOCE

Subject Title : Project Work & Viva VoceSubject Code : MET - 710Periods /Week : 03Period /semester : 45

A list of Topics suggested for project work1. Design and fabrication of small proto type metallurgical

Engineering equipment such as furnace etc. useful fordemonstration in the laboratory.

2. Study of the effect of various heat treatment processes onthe microstructures & properties of ferrous , non-ferrousmetals & alloys.

3. Collection of different ferrous and non-ferrous metal samplesand compile the metallographic data with photographs.

4. Identify castings and interpretation of defects on variousmetallic components by using NDT Techniques.

5. Preparation of Castings for different ferrous & Non-ferrousAlloys.

6. Any other project in consultation with industry / R & D Laboratory.

*****

2016 (C - 16) DIPLOMA IN METALLURGICAL ENGINEERING ...

Documents

Transcript of 2016 (C - 16) DIPLOMA IN METALLURGICAL ENGINEERING ...