Objectives

Performance analysis of practical energy conversion systems primarily from thermodynamic viewpoint, Analysis of environmental impact of energy conversion processes.

Course content

The course covers thermodynamic analysis of various energy systems such as combustion engines, solar, thermal, and nuclear power plants, electrochemical energy conversion, refrigeration, and air-conditioning. The course also includes environmental impact of energy conversion and sustainable technologies for energy conversion.

Total number of lectures: 40

Lecturewise breakup

1. Introduction: 1 Lecture

• Energy resources and conversion systems, world energy mix and status.

2. Thermal Energy Conversion: 15 Lectures

• Fuel and Combustion: fuel, stoichiometric ratio, heat of combustion, adiabatic flame temperature, chemical equilibrium, chemical kinetics, pollutant formation and control strategies.5 Lectures

• IC engines: Classification of IC engines, terminology, theoretical vs. actual engine, valve timing diagrams of four-stroke spark-ignition and compression ignition engine, supercharging, turbocharging, engine performance parameters, combustion in CI engine, combustion in SI engine, detonation and diesel knock. 5 Lectures

• Power Plant: Theoretical vs. actual thermal power plant (steam/gas cycle), regenerative stages and plant efficiency, Properties of coal, large (~100MW) coal-fired boilers, coal gasifier integrated gasification combined cycle (turbine details will not be covered). 5 Lectures

3. Nuclear Energy: 3 Lectures

• Nuclear fuel physics, fuel type, nuclear reactor type, Indian nuclear program.

4. Sustainable Energy Conversion: 13 Lectures

• Environmental Impact: Consequences of pollutants from classical energy conversion on the environment and climate. 1 Lectures

• Fuel Cells and Batteries: Thermodynamics of fuel cell and battery, current-voltage calculation, theoretical vs. actual performance, types of fuel cells and batteries, thermal management. 6 Lectures

• Solar thermal and photovoltaic:performance and efficiency calculation, solar thermal and thermochemical energy storage, photovoltaic, solar thermal integration with conventional power plant. 6 Lectures

5. Refrigeration and Air- conditioning: 6 Lectures

• Introduction to refrigeration and heat pump systems, cop, refrigerating effect, types of refrigerants, characteristics and performance, chemical and physical requirements, vapor compression cycle: real cycle, multi-stage and cascade refrigeration systems, vapour absorption refrigeration cycle, solar refrigeration systems, psychrometric processes, air-conditioning, process analysis using psychrometric charts .

Other topics: 2 Lectures

• Biomass, wind energy, tidal energy, geothermal energy, gas hydrates etc. (few important topics, as decided by the instructor, will be covered.

Recommended books

Textbooks

1. Principles of Energy Conversion, Culp A W, McGraw-Hill, India, 2nd ed.

Reference books

1. Energy Conversion Systems, Sorensen H, John Wiley & Sons, USA

2. Internal Combustion Engine Fundamental, Heywood J B, McGraw-Hill, USA, 2nd ed.

3. An Introduction to Combustion, Turns S T, McGraw-Hill, USA, 3rd ed.

4. Principles of Refrigeration, Dossat R, Pearson India, 4th ed.

5. Electrochemical Systems, Newman J, John Wiley & Sons, USA, 3rd ed.

Proposing instructors: Dr. M.K. Das, Dr. Santanu De, Dr. Abhishek Sarkar, Dr. A. K. Agarwal

Objectives

This course will help the student think about design of various mechanical components from the viewpoint of size, assembly, deformation, strength, various modes of failure, statistics, and environmental issues.

Course content

Dimensions and assembly, deformations and compliance, unexpected deformations, material failure, fatigue, extremely long-serving components, unexpected failure modes, statistical aspects, and environmental aspects.

Total number of lectures: 28

Lecturewise breakup

1. Discussion of ways in which a machine element may fail: 1 Lecture

• Shape, dimensions, or assembly 

• Deformations too large or small, component too compliant or not compliant enough

• Unexpected deformations (buckling)

• Plastic yielding or brittle fracture, leading to quick failure

• Fatigue (cyclic loading below yield and below buckling, ~1,000 to ~1,000,000 cycles)

• Extremely long-life goals not being met (more than 1,000,000 cycles)

• Other (becomes loose, jams or locks, has too much friction, vibrates, makes a noise)

2. Shape, dimensions, assembly: 4 Lectures

• Part drawing, subassembly drawing, production drawing, assembly drawing

• Different types of fits, geometric and dimensional tolerances

• LAB 1 Drawing, assembly, dimensions

3. Deformations too large or small, component too compliant or not compliant enough: 4 Lectures

• Helical compression springs for sizing and compliance

• Approximate deformation analysis of other components by hand; discussion of role of FEA

• How much should a bolt be tightened?

• LAB 2 Design of springs and bolts

• LAB 3 Approximate deformation analysis and comparison with supplied FEA results

4. Unexpected deformations (buckling): 2 Lectures

• Euler buckling (purely elastic), role of plasticity in buckling of shorter columns

• Sensitivity to imperfections. Presentation on other buckling problems (no calculations)

• LAB 4 Buckling problems

5. Plastic yielding or brittle fracture, leading to quick failure: 3 Lectures

• Ductile materials and brittle materials, stress concentration

• Design of bolted joints under tension and shear. Welded joints

• Local yielding that is contained. Yielding that cannot be contained. Limit load estimates

• LAB 5 Application of failure theories to any of the above

6. Fatigue. Design for fatigue: 5 Lectures

• What is fatigue? S-N curves. Nonzero mean loads. Fluctuating loads

• Physical phenomena. Localized yielding, hardening, crack initiation and growth

• Low cycle versus high cycle, strain versus stress controlled

• Role of flaws and microstructure.

• Empirical formulas. Various factors in design books

• Design example: fatigue in helical springs

• Fatigue under combined loading: simplest approaches

• Ideas of factor of safety in fatigue design

• LAB 6 Fatigue design 1

• LAB 7 Combined design problem involving previous lab topics

7. Extremely long-life goals: 5 Lectures

• Example 1: rolling element bearings

• How many cycles is typical?

• Types of bearings

• Sizing and life estimates from bearing catalogues

• Empirical correction factors

• Example 2: gearing

• Involute gear profile geometric parameters

• Elementary formulas for stress and fatigue

• Introduction to AGMA approach for design of spur and helical gears

• LAB 8 Involving bearings and gears

8. Other failure modes : 2 Lectures

• High levels of vibration. Removal of resonances, tuned vibration absorbers, dampers

• Whirling of shafts. Simple formulas

• LAB 9 Something from dynamics and vibrations as above

9. Accelerated testing and elementary statistical assessment: 1 Lecture

• LAB 10 Analysis of given data from an accelerated testing program

10. Design for a circular economy: 1 Lecture.

• Additional lab slots (11-14) may be used for supplementary lectures or for a project

Recommended books

1. Machine Component Design, RC Juvinall and KM Marshek

2. Shigley’s Mechanical Engineering Design, RG Budynas and JK Nisbett

Proposing instructors: Dr. A. Chatterjee, Dr. Shakti Gupta, Dr. A. Mimani

Pre-requisite:

ME 361.

Course Content:

Introduction to manufacturing, Manufacturing system concept. Manufacturing automation, FMS, CIMS, Flow lines and assembly systems, Automated storage / retrieval systems, AGV. Introduction to CAD/CAM, NC, CNC, DNC, Adaptive control. Manual and computer assisted part programming. Introduction to robots and their application in manufacturing. Process planning and Computer Aide Process planning. Group Technology, Opitz System and GT benefits. Material Management and Inventory control, MRP and MRP II. Just in time (JIT) and Lean manufacturing. Introduction to quality assurance and control, Statistical Quality Control, control charts, sampling. Total Quality Management. Manufacturing system simulation.

Lecturewise Breakup:

I. Introduction to manufacturing,  Manufacturing system concept: (1 Lecture)

II. Manufacturing Automation: (2 Lectures)

III. Flexible Manufacturing System: (2 Lectures)

IV. Computer Integrated Manufacturing System: (2 Lectures)

V. Flow Lines and Assembly Systems: (2 Lectures)

VI. Introduction to CAD/CAM: (1 Lecture)

VII. NC, CNC and DNC: (6 Lectures)

VIII. Adaptive Control: (1 Lecture)

IX. Manual and computer assisted part programming: (2 Lectures)

X. Automated storage / retrieval systems: (1 Lecture)

XI. AGV: (1 Lecture)

XII. Introduction to robots and their application in manufacturing: (3 Lectures)

XIII. Process planning and Computer Aide Process planning: (3 Lectures)

XIV. Group Technology, Opitz System and GT benefits: (2 Lectures)

XV. Material Management and  Inventory control: (2 Lectures)

XVI. MRP and MRP II: (2 Lectures)

XVII. Just in time (JIT) and Lean manufacturing: (2 Lectures)

XVIII. Introduction to quality assurance and control: (1 Lecture)

XIX. Statistical Quality Control, control charts, sampling: (3 Lectures)

XX. Total Quality Management: (2 Lectures)

XXI. Manufacturing System Simulation: (2 Lectures)

References:

1. Computer Integrated Design and Manufacturing by Nanua Singh, John Wiley.

2. Computer Aided Manufacturing by Chang, Wysk, Wang, Prentice Hall.

3. Computer Aided Manufacturing by Rao, Tewari, Kundra, TMH.