basic of mechanical
TRANSCRIPT
-
7/24/2019 Basic of Mechanical
1/49
TRAINING DETAILS
Day: 1
Date: 25. 03.2014
Topics Covere Stress
Strai!
Types o" Stress A! Strai!
#o$!%&s 'o$($s )actor o" sa"ety
De"or*atio!
Stress:
Stress is Force Acting per Unit area or a resistive Force
offered Against the Force Applied.
Types o" stress:
Tensile Stress (It is Caused By Pull Load)
Copressive Stress(It is Caused By Push Load)
Shear Stress(It is caused At Surface )
Theral Stress(!ue to Teperature)
Strain:
-
7/24/2019 Basic of Mechanical
2/49
Strai! is ca$se D$e to Stress. It is T+e Ratio
,et-ee! C+a!%e I! i*e!sio!s A! ri%i!a(
Di*e!sio!. It +as !o $!its
Deformation:
T+e c+a!%e i! Di*e!sio! is ca((e
De"or*atio!
Elastic Limit:
It is /oi!t +ere Stress a! strai! Ratio! Is
co!sta!t .et-ee! t+is Li*it t+e 'ateria(
e+aves E(astica((y
Yield Point:
It is t+e poi!t -+ere t+e 'ateria( starteDe"or*i!% /(astica((y
Ultimate Stress:
It is t+e 'ai*$* Stress +ic+ A *ateria(
ca! -it+ Sta!
Youngs Modulus:
it+i! T+e E(astic Li*it Stress is Direct(y
/roportio!a( to Strai!. It is ooe&s La-.
/roportio!a( Co!sta!t is !o-! as #o!%&s
'o$($s
-
7/24/2019 Basic of Mechanical
3/49
Factor of Safety:
It is ratio ,et-ee! (ti*ate Stress a!
ori!% Stress. +i(e Desi%!i!%6 )actor o"
sa"ety is very i*porta!t. T+e Avera%e 5
*$st ,e *ai!tai!e.
-
7/24/2019 Basic of Mechanical
4/49
Day: 2
Date: 27.03.2014
Topics Coered
Stress Strai! C$rve
Str$ct$ra( A! its asics
Stress!Strain Cure
Stress strai! c$rve is $se -+i(e esi%!i!%
"or a!y *ateria( .!er Loa test t+is c$rve
is ra-! to 8! t+e e(astic (i*it6 yie( poi!t6
(ti*ate Stress a! ,reai!% /oi!t etc.
-
7/24/2019 Basic of Mechanical
5/49
Structural and its "asics:
To ,$i( a str$ct$re -e !ee so*e /ro8(e
(ie
ea*s
C+a!!e(s
A!%(es
SS9a((o- str$ct$ra( sectio!
/(ates
"eams:
ea* Is Str$ct$ra( *e*,er -+ic+ is
s$pporte a! carries (oa -+ic+ is Ri%+ta!%(e to t+e (e!%t+. 'ost(y ;I< ,ea* is $se
,eca$se it +as +i%+ *o*e!t o" i!ertia
-
7/24/2019 Basic of Mechanical
6/49
T+ese ,ea*s are speci8e ,y I!ia!
Sta!ar As
IS' 100 9I!ia! Sta!ar 'ei$*
ea*s IS= 125 9I!ia! Sta!ar >$!ior ea*s
ISL 150 9I!ia! Sta!ar Li%+t ea*s
IS 200 9I!ia! Sta!ar ei%+t
ea*s IS 225 9I!ia! Sta!ar eavy
ea*s
100 Speci8es t+e ept+ o" t+e sectio!
C#annel:
Channel is a constructional aterial "ith cross section
as C shape
Channel are specified #y Indian Standard as
-
7/24/2019 Basic of Mechanical
7/49
o IS'C 100 9I!ia! Sta!ar *ei$*
c+a!!e(
o IS=C 150 9I!ia! Sta!ar >$!iorC+a!!e(
o ISLC 200 9I!ia! Sta!ar (i%+t
c+a!!e(
$ngle:Angle is also a constructional aterial "ith a Cross
section $L%
%allo& Structured Section:
&allo" Structured Section Is a constructional 'aterial
"hich is a closed section egsteel pipe* tu#e
Parallel flange Beas and coluns are specified #y
British and +uropean Standards such as
-
7/24/2019 Basic of Mechanical
8/49
UC ,-./,-./.0 (British Standard)
UB -00/.,1/2.(British Standard)
IP+A 311 (+uropean Standard)
&P+ 411 (+uropean standard)
Types of 'eams "y Supports:
Si*p(y s$pporte
ver+a!%i!%
Ca!ti(ever
)ie
Co!ti!$o$s
-
7/24/2019 Basic of Mechanical
9/49
Plates:
Plates are ordinary sheet or plates of various thic5ness
Its thic5ness is selected according to the load applied
Types of Load $cting on "eams:
Concentrated load or Point load
Uniforly distri#uted load
Uniforly varying load
Moment of (nertia
-
7/24/2019 Basic of Mechanical
10/49
'oent of inertia of a #ody is defined as the resistance
offered against the rotation or capacity of cross section
against #ending
Day: 3
Date: 2?.03.2014Topics coered
'aterial and its selection
Car#on steel
Alloy Steel
-
7/24/2019 Basic of Mechanical
11/49
Car'on Steel:
Car#on steel is an alloy of iron and car#on "hich car#on are
the ain alloying aterials 6ther aterials are added such asanganese* copper* silicon in lo" a7iu percentage
According to The car#on content there are three categories
Sn
o
Types Coposition
, Lo" car#on steel C 11-8 to 1.-8
'n up to 148
. 'ediu Car#on steel C1.98 to 1-48
'n 138 to ,3-8
0 &igh Car#on Steel C1--8 to 19-8
'n108 to 198
4 :ery &igh Car#on
Steel
C1938 to .,8
$lloy steel:
Alloy Steel is steel in "hich t"o or ore alloying
su#stance is added other than car#on to achieve the
desired properties It has t"o types
Low alloy steelAlloying eleents less than ,1-8
-
7/24/2019 Basic of Mechanical
12/49
High Alloy steelAlloying eleents ore than ,1-8
)rades and Standard:
*+,-.+-/.,01
Materials Carbon steel Alloy steel
Plate;sheets SA -,- >>
Bolt* @ut*
asher ISI030*34*3=
>>>
Day: 4
Date: [email protected]
Topics coered
, Stain less Steel
-
7/24/2019 Basic of Mechanical
13/49
. &astelloy
0 First angle proection and third angle proection
,- Stainless steel:
A Stainless steel is a steel alloy of iniu ,1-8of
chroiu in assIt is rust less and ino7yda#le
Commonly Used Grades
SS 014
SS014L
SS014&
SS.14
SS010
SS0,3
SS0,3L
SS0C?,.
SS401
SS44,
Types of Stainless Steel:
i Ferrritic
ii Austenitic
iii 'artensitic
iv !uple7
v Precipitation &ardening
-
7/24/2019 Basic of Mechanical
14/49
i- Ferritic:o 411 Serieso Chroiu is uch (.=8)
o &igh resistance to corrosion
o They are agnetic
o Cannot #e hardened #y heat treatent
o Used in sea "ater
o Used for a5ing car tri and +7haust syste
ii- Martensitic:o Siilar to ferritic*#ut car#on content differ ie* ,8
o &igh strength
o 'oderate corrosion ?esistance
o 'oly#denu and nic5el is addedo &arder and little 'agnetic
o Used in spindle* 5nifes* Shaft* surgical instruent
iii- $ustentic:o 'ost coon steel
o Corrosion resistanceo !uctile and 'allea#le
o Used in 5itchen sin5s and cheical eDuipentEs
i- Duple2:
-
7/24/2019 Basic of Mechanical
15/49
Fored #y i7ing the #asic coponents of austenitic
and ferriticsteel
o It contains &igher level of chroiuo Siple to "eld
o +asily fored to specific shapes
o Best Duality
o Used for tools and achinery in arine condition
- Precipitation %ardening:
Basically Austenitic #y adding other eleents to get
desired properties once added it #ecoe e7treely
tough* dura#le and hard "earing
Used in Aircrafts Parts and Pups
/- %astelloy:
&astelloy is the alloy of nic5el* chroiu* and
oly#denuIt has high o7idation resistance* fa#ric
a#ility* and high teperature strength
Composition:
-
7/24/2019 Basic of Mechanical
16/49
Ni --8
Mo -,- ,=8
Cr ,4- ,3-8
Fe 4 =8
W 0 4-8
Uses:
Pollution Control
Cheical processing
aste treatent 'arine +ngineering
Pulp and paper production
Sta!ar $se "or aste((oy is
C/34
)rades and Standard :
* +,-.+-/.,01
Materials
Stainless Steel
Plate;sheets SA 240 9GRADE
-
7/24/2019 Basic of Mechanical
17/49
Pipe SA 3129GRADE
Tu#eSA 27@
Structural
?od SA 2?79GRADEBolt* @ut* asher AISI 317 9-as+er
A13 ? 9o(t
A14 @ 9!$t
Using )rades: SS 204
SS 304
SS 317
SS 317L
Properties ofmaterials:i. /+ysica( propertiesii. 'ec+a!ica( properties
iii. T+er*a( properties
-
7/24/2019 Basic of Mechanical
18/49
i- P#ysical properties: co!$ctivity Te!si(e Stre!%t+
#ie( Stre!%t+
'e(ti!% poi!t
)reeBi!% poi!t
ii- Mec#anical properties: &ardness
To$%+!ess
iii- T#ermal property:
E!tropy E!t+a(py
+- First $ngle and T#ird $nglepro5ection:
First $ngle
,>ect (ies i! t+e 8rst $ara!t
T+e vie-s are iere!t "ro* t+ir a!%(e
ie-erFo,>ectFp(a!e o" pro>ectio!
-
7/24/2019 Basic of Mechanical
19/49
T#ird $ngle pro5ection
T+e o,>ect (ies i! t+ir $ara!t
T+e vie-s are iere!t "ro* 8rst a!%(e
ie-erFp(a!e o" pro>ectio!Fo,>ect
Sym'ol for Pro5ection:
Day: 5 7Date: 2.03.2014 31.03.2014
Topics Coered:
!it co!versio!s
-
7/24/2019 Basic of Mechanical
20/49
Sta!ars a! Graes
!it co!versio!
,Pressure
.Flo" rates
0Teperature
,- Pressure
1pasca(H0.00014503 /si
1arH14.503 /si
1/siH0.07@7 ,ar
1 ,arH100000 N *J
/- Flo& rates
1 (iter+o$rH0.2741? %a((o!+o$r
1 %a((o!+o$rH3.?@5 (itre+o$r
1*i((i(itre+o$rH0.001(itre+o$r
-
7/24/2019 Basic of Mechanical
21/49
1*i((i(itre+o$rH0.0002741? %a((o!+o$r
1(itre+o$rH1000 *i((i(itre+o$r
1 c$,ic *etresecH3700000 %+o$r
1 c$,ic *etersecH1000 %sec
+- Temperature
1 e%ree Ce(si$sH33.@ )
1 )a+re!+eitHF1?.22 e%ree Ce(si$s
-
7/24/2019 Basic of Mechanical
22/49
Day: 3
Date: .,-.0-/.,0
Topics Coered:
1. 6elding2. Types of &eld 5oints3. 7omenclature of &eld4. Edge preparation5. 6elding sym'ol
7. 6elding mac#ines?. 6elding Process
6elding:
e(i!% is t+e process o" >oi!i!% t-o si*i(ar *ateria(s ,y
+eati!% process.
Types of &eld 8oints:
e( >oi!ts ca! ,e c(assi8e accori!% to
Type o" -e(
/ositio! o" -or piece
Le!%t+ o" -e(
y Type o" -e( it ca! ,e c(assi8e i!to
"utt &eld Fillet 6eld
Plug &eld
Slot &eld
Seam &eld
Spot &eld
-
7/24/2019 Basic of Mechanical
23/49
y t+e positio! o" -e(
"utt 5oint Lap 5oint
T 5oint
Corner 5oint
Edge 5oint
y t+e (e!%t+ o" t+e -e(:
Continuous 6eld
(ntermittent 6eldo C#ain "ot# Sides
o Staggered
6eld 7omenclature:
-
7/24/2019 Basic of Mechanical
24/49
6elding Sym'ols:
Edge preparation:
It is the preparation #efore "elding to increase the strength of the "eld
-
7/24/2019 Basic of Mechanical
25/49
-
7/24/2019 Basic of Mechanical
26/49
6elding Process:
$rc 6elding Process:
Ato*ic yro%e! e(i!%
Car,o! Arc e(i!% Gas *eta( Arc -e(i!%
/(as*a Arc -e(i!%
92y Fuel )as 6elding:
y acety(e!e e(i!%
y yro%e! e(i!%
esistance 6elding:
Resista!ce Spot e(i!%
Resista!ce Sea* e(i!%
9t#er 6elding Process:
E(ectro! ea* e(i!%
Laser ea* e(i!%
-
7/24/2019 Basic of Mechanical
27/49
Types of &elding Mac#ines:
TIG -e(i!% 'ac+i!es'IG -e(i!% 'ac+i!esS'A e(i!% 'ac+i!esyF"$e( e(i!% 'ac+i!es
-
7/24/2019 Basic of Mechanical
28/49
Day: ;
Date: ./-.0-/.,0
Topics Coered:
Drilling
Milling
)rinding
S#aping
Drilling:
!rilling is the process of creating a hole in a "or5 piece using drill
#it
Types o" Dri((i!%:
Spot Drilling
Centre Drilling
Deep hole drilling
Gn Drilling
!repanning
Mi"ro drilling
#ibration Drilling
Spot Dri((i!%:
Spot drilling is the process of drilling a hole "hich guide
the final hole
-
7/24/2019 Basic of Mechanical
29/49
Ce!tre Dri((i!%:
The purpose of center drilling* it acts as the center for variousoperations
Deep o(e Dri((i!%:
!eep hole drilling is used "here the length of the hole is ,1 ties
greater than the dia of the hole
G$! Dri((i!%:
-
7/24/2019 Basic of Mechanical
30/49
Milling:
'i((i!% is t+e process o" re*ovi!% *ateria( $si!% *$(ti poi!tc$tti!% too(
Types of Milling Mac#ines:
%ori
-
7/24/2019 Basic of Mechanical
31/49
$'rasies in )rinding 6#eels:
Sand Stones Emery
Diamonds
Corundum $luminum o2ide
Silicon Car'ide
-
7/24/2019 Basic of Mechanical
32/49
S#aping Mac#ines:
S+api!% is t+e i! o" reciprocati!% *ac+i!e -+ic+
$ses a si!%(e poi!t c$tti!% too( to re*ove *eta(s.
Types of S#aper Mac#ines:
%ori
Date: .+-.0-/.,0
-
7/24/2019 Basic of Mechanical
33/49
Topics Coered:
Basic Concepts of Therodynaics
La"s of therodynaics
"asic Concept of
T#ermodynamics:
!hermodynami"sis study of heat and its relation to
"or5 and energy Thero&eat* !ynaicsPo"er
System$ Srronding$ %ondary&
Therodynaic syste* or system$is defined as aDuantity of atter or a region in space chosen for
study
The region outside the syste is called the
Srrondings'
The real or iaginary surface that separates the syste fro its surroundings is called the
%ondary'
-
7/24/2019 Basic of Mechanical
34/49
Types of System:
T+e syste* i! -+ic+ t+e e!er%y tra!s"er a!
*ass tra!s"er taes p(ace is ca((e 9pen
systeme.%. Co*pressor
T+e syste* i! -+ic+ o!(y e!er%y tra!s"er
taes p(ace is ca((eClosed System. ere
*ass tra!s"er oes!&t taes p(ace.
T+e Syste* -+ic+ oes!&t ec+a!%e a!ye!er%y a! *atter is ca((e (solated
system
Types of Energies:
Potential energyis t+e e!er%y store -it+i!t+e o,>ect e.%. E!er%y store i! t+e spri!%6 a* etc.
()* mass + g + height
?inetic energyis t+e e!er%y o" *otio!. Every
o,>ect i! *otio! +as i!etic e!er%y
-
7/24/2019 Basic of Mechanical
35/49
(nternal energyis t+e e!er%y associate -it+ t+e
i!ter!a( *o(ec$(es o" t+e s$,sta!ce.
La&s of T#ermodynamics:
First la&o" t+er*oy!a*ics states t+at
!et -or tra!s"er is e$a( !et +eat tra!s"er
i.e. e!er%y ca! !eit+er ca! create !orestroye
Second la& 'y @elin plan@says t+at
it is i*possi,(e to co!str$ct a +eat po-er
e!%i!e -+ic+ -ors o! a cyc(ic process
-+ic+ co!verts t+e a,sor,e +eat "ro* a
reservoir i!to e$iva(e!t a*o$!t o" -or.
Second la& 'y clausiussays t+at it is
i*possi,(e to tra!s"er +eat "ro* co( ,oy to
+ot ,oy -it+o$t t+e $se o" eter!a( -or.
T#ird la&says t+at t+e e!tropy o" t+e
per"ect crysta( at a,so($te Bero te*perat$reis Bero
-
7/24/2019 Basic of Mechanical
36/49
Day: ,.
Date: .0-.0-/.,0
Topics Coered:
)ntropy
)nthalpy
Spe"i,i" heat
nternal )nergy
Latent Heat
Sensible Heat
Dimensioning .les
Ent#alpy:
+nthalpy is the su of internal energy and flo" "or5
H
*
U/
-
7/24/2019 Basic of Mechanical
37/49
(
#
& +nthalpy
UInternal +nergy
Ppressure
: :olue
Entropy: +ntropy is the therodynaic property and it depends upon the
change in teperature #y heat transfer
S
*
0
1!
S +ntropy
&eat Transfer
T Teperature
(nternal Energy:
-
7/24/2019 Basic of Mechanical
38/49
It is the total energy Possessed #y a #ody Thus internal energy
is the su of potential energy and 5inetic energy of the
olecules of the #ody
SpeciAc %eat:
Specific heat is the heat reDuired to raise the
teperature of the unit ass of the su#stance to one degree
Celsius
Latent %eatB
It is the aount of heat released or a#sor#ed during the change
of state of su#stance at constant teperature
Sensi'le %eat:
Sensi#le heat is the energy reDuired to change the teperature
of a su#stance "ith no phase change
Dimension ules:
, Avoid placing any diensions inside the part unless there is
no other option
. Avoid diensioning to hidden features
0 Avoid contact of values
4 Al"ays place diension to the ost descriptive vie"
-
7/24/2019 Basic of Mechanical
39/49
- !iension rounded corners G arc features as radial
3 If sae value is repeated any ties* then use a general
note
= Al"ays diension holes in their circular vie"
2 !iension cylindrical o#ect as diaeter in their rectangular
vie"
9 For etric diensions less than , does place a Hero at
decial Point
,1 For inches diensions less than ,% dont place a Hero
introduction at decial Point
,, 6verall diensions should #e outside of saller
diensions
,. !o not duplicate diensions to avoid using on necessary
,0 !iension line should never intersect other diension line
,4 Center Line should not e7tend fro vie" to vie"
,- Arro" heads 0 J ,
Day: ,,
Date: .-.0-/.,0
-
7/24/2019 Basic of Mechanical
40/49
Topics Coered:
Conduction
Convection
?adiation
Cooling
Lu#ricants
Cond"tion&
The transfer of heat fro one su#stance to
another #y direct contact
+7aples
Touching the &ot Pan
Touching the &ot su#stance
Con2e"tion&
Convection is the oveent of olecules
"ithin fluids
+7aples Boiling of ater and Convection happened #et"een the
olecules
.adiation&
-
7/24/2019 Basic of Mechanical
41/49
+nergy that is radiated or transitted in the
for of raysIt is the heat transfer #y electroagnetic
"aves
+7aples
'icro"ave oven
Light Bul#
&eat fro a Fire
Cooling: Cooling is for reoval of heat produced #y the
oving parts and Burning of fuel #y the circulation of the
coolant
(roperties o, the "oolants&
&igh heat transfer rate high #oiling point
Lo" elting point
Lo" po"er reDuireents for puping
@onto7ic
@onreactive
!ypes o, "ooling system&
LiDuid Cooling, Thero syphon Cooling Syste
. Forced Circulation cooling Syste
Air Cooling
-
7/24/2019 Basic of Mechanical
42/49
Lu'rication: Lu#rication is the process to reduce "ear #et"een
oving parts using lu#ricants
(roperties o, the Lbri"ants&
It should have &igh :iscosity
Its 6iliness Should #e &igh
It should have &igh Flash Point
It should #e :olatile
It Should Posses !elergency Property
It should Posses !eulsi#ility
!ypes o, Lbri"ating System&
Pet roil syste
Pressure lu#rication Syste
Splash type Lu#rication Syste
Sei pressure Lu#rication Syste
-
7/24/2019 Basic of Mechanical
43/49
Day: ,/,+
Date: .3-.0-/.,0
!opi"s Co2ered&
Properties of fluids
Types of flo"
Flo" through pipes and its losses
Pups and its types Pipe standard as per A@SI B,3,1
(roperties o, ,lid&
3' Density or Mass Density
!ensity of the su#stance is the ass per unit volue
4' Weight Density
eight density is the "eight per unit volue
5' Spe"i,i" 2olme
Specific volue is the ratio of the volue to its assIt is the
reciprocal of !ensity
6' Spe"i,i" gra2ity
It is the ratio of the density of the su#stance to the density of the
standard su#stance
7' Compressibility
It is the A#ility to copress a su#stance #y Pressure
8' #apor pressre
-
7/24/2019 Basic of Mechanical
44/49
:apour pressure is the pressure e7erted #y the vapour in
therodynaic eDuili#riu to its phase in a closed syste
9' Cohesion
Cohesion is the property attraction of the li5e olecules of the
su#stance
:' Adhesion
Adhesion is the property of the su#stance for the attraction
#et"een disli5e olecules
;' Sr,a"e tension
The cohesive force #et"een the liDuid olecules is responsi#le
for the phenoenon surface tension It is the property of the surface of
the liDuid allo"s resisting the e7ternal force
3
-
7/24/2019 Basic of Mechanical
45/49
Uni,orm ,low&
Unifor flo" is the flo" "here the velocity of the fluid is constant
Non-Uni,orm Flow&
It is the flo" "here the velocity of the fluid is varia#le
!rblent Flow&
Flo" of fluid is KigHag* flo" layers intersect each other
Laminar Flow&
Flo" layers are parallel to each other throughout the flo"
Flow throgh (ipes&
Flo" through pipes is flo" of fluids through closed conduit* !ue to
pressure it occupies the "hole space* if it occupies the "hole space it is
called pipe flo" and "hen its flo" "ith the space it is called channel
flo"
Losses in ,low throgh pipes&
Loss in head due to pipe friction Loss in head due to sudden enlargeent
Loss in head due to sudden contraction
Loss of head due to entry into pipe
Loss of head due to e7it fro pipe
Loss of head due to o#struction
Loss of head due to change in direction
Loss of head due to
-
7/24/2019 Basic of Mechanical
46/49
/$*ps
/ositiveDisp(ace*e!t
Rotary
)(e2i,(eI*pe((er
/ro%ressi!%Cavity
/erista(tic
Ea!e
Ro((er
Gear
Lo,e
Scre-
Reciprocati!%
/isto!
Diap+ra%*
/($!%er
Ki!etic
T$r,i!e
Ce!tri"$%a(
Loss of head due to various pipe fitting
(mp and its types&
(ositi2e displa"ement pmps&
-
7/24/2019 Basic of Mechanical
47/49
This type of pups a5es a trapping of fi7ed aount of
fluid and forcing the trapped aount into the !ischarge
Chara"teristi" o, positi2e Displa"ementpmps&
Positive !isplaceent pup can theoretically produce
the sae flo" at given rpSo it is the constant flo"
device 6n increase in pressure lea5age happens
It cannot #e operated "hen discharge valve closes Itay daage the pup
?elief valve and safety valve is reDuired at discharge side
to avoid daage of pups
Chara"teristi" "r2e ,or (ositi2e Displa"ement
(mps&
-
7/24/2019 Basic of Mechanical
48/49
The dashed line sho"s actual positive displaceent pup perforance This
line says that the discharge pressure of the pup increases* soe aount of liDuid
"ill lea5 fro the discharge* reducing the flo" rate of the pup The rate at "hich
liDuid lea5s fro the discharge to its suction is called Slippage'
(ositi2e Displa"ement (mps are sed when=
,) :iscosity of the fluid is lo".) &igh efficiency is needed
0) e used varia#le viscosity application4) Suction lift application is needed
-
7/24/2019 Basic of Mechanical
49/49