Introduction to Mechanical Engineering

INTRODUCTION TO MECHANICAL
ENGINEERING
24ESC144/244
Dr. madhu p
Assistant professor
Department of mechanical Engineering
Malnad college of engineering, hassan

Department of Mechanical Engineering, MCE, Hassan 1

Introduction to Mechanical Engineering

Course Objective:
To introduce fresh entrants of engineering courses to the principles and
fundamentals of Mechanical Engineering
Course Outcomes (COs){with mapping shown against the Program Outcomes
(POs)}
Upon completion of the course, students shall be able to:
CO1 - explain the concepts of mechanical engineering, energy sources, and
engineering materials
CO2 - explain the working principle of IC engines, electric and hybrid vehicles
CO3 - describe non-traditional and modern manufacturing techniques and
illustrate manufacturing components using CNC, additive manufacturing, and
joining processes
CO4 - understand the basic principles of automation, mechatronics and robotics

Department of Mechanical Engineering, MCE, Hassan 2

Introduction to Mechanical Engineering

Scheme of Evaluation (Theory

Courses) Weightage
Portions for CIE Mode of Evaluation
in Marks

CIE - 1 Descriptive Test 10

Syllabus to be decided by the course
CIE - 2 coordinators such that all the COs shall be Descriptive Test 10
covered
CIE - 3 Descriptive Test 10

Industrial Visit / Case study/

Activity Minimum of two activities to be conducted Practical/ 20
Working model

Total 50

Minimum marks to Minimum Average marks

Examination Maximum marks
be scored to qualify

Tests 30 12 (> = 40%)

CIE
Activity 20 08 (> = 40%)
40 (> = 40%)
SEE 50 17.5 (> = 35%)

Department of Mechanical Engineering, MCE, Hassan 3

Introduction to Mechanical Engineering

TEXTBOOK:
Elements of Mechanical Engineering, K R Gopala Krishna, Subhash
Publications, 2008.
Elements of Workshop Technology (Vol. 1 and 2), Hazra Choudhry and
Nirzar Roy, Media Promoters and Publishers Pvt. Ltd., 2010.

REFERENCES:
An Introduction to Mechanical Engineering, Jonathan Wickert, 2nd
edition, Cengage Learning 2006, ISBN-10: 1-111-57682.
Elements of Mechanical Engineering - K P Roy, S K H Choudhry, A K H
Choudhry, Roy Media promoters and publishers, Mumbai, 7th edition,
ISBN: 4567145216, 1234567145210.
Electric and Hybrid vehicles by A. K. Babu Khanna Publications.
Robotics, Appuu Kuttan K K. International Pvt. Ltd, volume 1.
Introduction to Mechatronics, Appuu Kuttan K K, Oxford University Press,
2007.

Department of Mechanical Engineering, MCE, Hassan 4

 Introduction to Mechanical Engineering

Module - 1
Introduction to Mechanical Engineering
Role of Mechanical Engineers in Industries and Society - Emerging Trends
and Technologies in different sectors such as Energy, Manufacturing,
Automotive, Aerospace, Automation, Industry 4.0 and applications in
Artificial Intelligence (AI) and Machine Learning (ML).
Energy Sources
Introduction and applications of Energy sources like Fossil fuels, nuclear
fuels, Hydel, Solar, wind, and biofuels.
Engineering Materials
Classification of Engineering Materials, Types and applications of Ferrous &
Nonferrous Metals, silica, ceramics, glass, graphite, diamond and polymer,
composite materials.
Activity
1. Visit to any manufacturing/aero/auto industry or any power plant
2. Demonstration of Tensile testing using UTM
Department of Mechanical Engineering, MCE, Hassan 5
Introduction to Mechanical Engineering

Lesson Plan:
Lecture
Topics
Hour
1 Introduction to Mechanical Engineering
Introduction to Mechanical Engineering: Role of Mechanical
2
Engineers in Industries and Society
Energy Sources: Introduction and applications of Energy
3
sources like Fossil fuels and nuclear fuels.
Energy Sources: Introduction and applications of Hydel and
4
Solar energy
Energy Sources: Introduction and applications of wind energy
5
and biofuels.
Engineering Materials: Classification of Engineering Materials,
6
Types and applications of Ferrous & Nonferrous Metals.
Engineering Materials: Silica, ceramics, glass, graphite,
7
diamond and polymer.
8 Engineering Materials: Composite materials.
9 Activity: Demonstration of Tensile testing using UTM
10 of Mechanical
Department Activity: Demonstration
Engineering, MCE,of Tensile
Hassan testing using UTM 6
Introduction to Mechanical Engineering

Introduction to Mechanical Engineering

Mechanical engineering is a branch of
engineering combines the principles of physics and
mathematics with material science, to design, analyze,
manufacture and maintain mechanical systems.

Technically, mechanical engineering is the application of

the principles and problem-solving techniques of
engineering from design to manufacturing to the
marketplace for any object.

Mechanical engineers analyze their work using the

principles of motion, energy, and force-ensuring that
designs function safely, efficiently, and reliably, all at a
competitive cost.
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Introduction to Mechanical Engineering

Disciplines within mechanical engineering include but are not

limited to
• Biotechnology
• Acoustics
• Manufacturing and additive
• Design
manufacturing
• Aerospace
• Composites
• Energy
• Nanotechnology
• Automation
• Computer Aided Design (CAD)
• Ergonomics
• Production planning
• Automotive
• Control Systems
• Human health
• Structural analysis

And many more…..

Department of Mechanical Engineering, MCE, Hassan 8

Introduction to Mechanical Engineering
Role of Mechanical Engineers in Society
Transportation
The distance that once took days for us to cover using biological modes of
transport can now be achieved in mere hours and minutes with the aid of
automobiles.

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Introduction to Mechanical Engineering
Role of Mechanical Engineers in Society
Agricultural mechanization
The agricultural field too reaped the benefits of modified mechanized
farming machinery to increase the production and reduce the time taken to
do so manually.
Without the implementation of the modern machinery like water pumps,
tractors, harvesters, etc. developed by the mechanical engineers, our society
would have been still hobbled and would have never attained its full
potential.

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Introduction to Mechanical Engineering

Role of Mechanical Engineers in Society

Agricultural mechanization

Department of Mechanical Engineering, MCE, Hassan 11

Introduction to Mechanical Engineering

Role of Mechanical Engineers in Society

Household appliances
Comfortable life with the help of appliances such as heaters, air conditioners,
and refrigerators.
Every workplace in the modern world has a ventilated central cooling and/
or heating system. Such systems are also used to purify the air and help in
manufacturing processes that require a specific temperature.

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Introduction to Mechanical Engineering

What you think of this appliance?

Electronic appliance

Thermal Engineering

Department of Mechanical Engineering, MCE, Hassan 13

Introduction to Mechanical Engineering

What you think of this appliance?

Electronic appliance

Design Engineering, Mechanics

Department of Mechanical Engineering, MCE, Hassan 14

Introduction to Mechanical Engineering

What you think of this picture?

Carpenter

Industrial engineering, Ergonomics

Department of Mechanical Engineering, MCE, Hassan 15

Introduction to Mechanical Engineering

What you think of this device?

Clock

Mechanics, Material Science

Department of Mechanical Engineering, MCE, Hassan 16

Introduction to Mechanical Engineering

What you think of this picture?

Pen

Hydraulics

Department of Mechanical Engineering, MCE, Hassan 17

Introduction to Mechanical Engineering

What you think of this picture?

Locks

Design, Mechanics

Department of Mechanical Engineering, MCE, Hassan 18

Introduction to Mechanical Engineering

What you think of this picture?

Guitar

Acoustic Engineering

Department of Mechanical Engineering, MCE, Hassan 19

Introduction to Mechanical Engineering

What you think of this picture?

Bungee jumping

Structural Analysis

Department of Mechanical Engineering, MCE, Hassan 20

Introduction to Mechanical Engineering

What you think of this picture?

Elevators

Mechanics, Mechatronics

Department of Mechanical Engineering, MCE, Hassan 21

Introduction to Mechanical Engineering

Role of Mechanical Engineers in Society

Waste management
Waste management has also played a pivotal role in our society by keeping
it clean, hygienic and free of diseases.
Waste disposal trucks, treatment facilities, and water purification systems
are all significant contributions of mechanical engineers towards our society.

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Introduction to Mechanical Engineering
Role of Mechanical Engineers in Society
Other sectors
Healthcare industry in creating technologies that are helping doctors and
humankind through solving various healthcare problems and creating
future solutions.
Healthcare devices, individualized medicines as well as surgical devices are
being developed by mechanical engineers using 3D-printing technologies.
Mechanical engineers also involve in developing green technology,
sustainable energy, clean air, drinking water, green transportation, safe
waste disposal and renewable energy.

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Introduction to Mechanical Engineering

Role of Mechanical Engineers in Energy Sector

Mechanical engineers help hydropower or hydroelectric power plants find
efficient ways of extracting electricity from strong water currents.
They design, and develop essential machines and hardware, such as turbines,
generators, and hydro-pressure and control mechanisms.
Mechanical engineers can work in every stage of renewable energy
development and distribution.
From developing methods that lower the cost of manufacturing silicon for
solar panels to designing more optimal ways to construct wind farms,
mechanical engineers are critical to lowering the cost of renewable energy
infrastructure.

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Introduction to Mechanical Engineering

Role of Mechanical Engineers in Energy Sector

Department of Mechanical Engineering, MCE, Hassan 25

Introduction to Mechanical Engineering
Manufacturing Sector
Mechanical engineers in manufacturing works to bring the idea and designs
into reality by proper selection of material, machine, and manufacturing
process.
Involves right from the selection of materials and tooling, manufacturing,
planning process layouts, plant layouts, equipment specification, tool design,
value analysis, cost control, final assembly, inspection, packing, dispatch/
shipment.

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Introduction to Mechanical Engineering

Automotive Sector
Mechanical engineers drive the automotive industry. From 80-seater buses
to single seat F1 cars, they design bodyshells, wheelsets and combustion
systems for every type of moving vehicle.
Mechanical engineering in the automotive industry is key to developing new
types of vehicles, updating models, repairing existing vehicles and
implementing new functionalities and safety features.

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Introduction to Mechanical Engineering

Aerospace Sector
With the design, development, production and testing of aircraft, spacecraft,
and related equipment and systems.
Evaluate designs to ensure products meet engineering principles, customer
requirements, and environmental challenges.
Missiles or Rockets.

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Introduction to Mechanical Engineering

Automation
Engineers are responsible for the design, development and implementation
of automated systems that help manufacturing processes run efficiently.
This includes the design and development of modular components that their
team can easily integrate into the manufacturing process.
Develop or modify existing production or testing equipment to make it more
efficient or help implement new methods.

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Introduction to Mechanical Engineering

Industry 4.0

Mechanical engineers are working hand in hand with computers to make

machines communicate without human involvement keeping the possibility
of developing a smart factory.

Industry 4.0, also known as the fourth industrial revolution, refers to the
ongoing transformation of traditional industries through the integration of
advanced technologies and digitalization.

It is characterized by the convergence of physical systems with digital

technologies, enabling a new level of connectivity, automation, and data
exchange in various sectors, including manufacturing, logistics, healthcare,
and more.

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Introduction to Mechanical Engineering

Industry 4.0

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Introduction to Mechanical Engineering

Industry 4.0

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Introduction to Mechanical Engineering

Energy
Energy is a Greek word “Energia”, meaning capacity to do work. There are
two forms of energy.

Department of Mechanical Engineering, MCE, Hassan 33

Energy sources

Fig. Energy
sources
Energy sources

Fig. Capital and Celestial

energy
Introduction to Mechanical Engineering

Classification of Energy Sources

Renewable Energy sources &
Non-Renewable Energy sources

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Introduction to Mechanical Engineering

Renewable Energy sources

The renewable sources of energy are defined as the energy sources which
are continuously produced in nature and are essentially inexhaustible or
non-depletable.
These energy sources replenish themselves naturally in a relatively short
time and therefore will always be available.
E.g. of renewable energy sources: direct solar energy, wind energy, tidal
energy, hydel energy, ocean thermal energy, bio energy, geothermal energy,
peat, fuel wood, fuel cells, solid wastes, hydrogen energy etc.

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Introduction to Mechanical Engineering
Non-Renewable Energy sources
Non-renewable energy sources are those natural resources that are
available in limited quantity and these resources cannot be renewed in
short durations.
Eg: Fossil fuels (coal, petroleum, and petroleum products), nuclear fuels, and
heat traps

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Introduction to Mechanical Engineering

Differences between Renewable and Non-Renewable Energy

Sources
Renewable Energy Non-Renewable Energy
Factor
Sources Sources

Exhaustibility/
Inexhaustible Exhaustible
Inexhaustibility

Availability Abundantly and freely

Not abundantly
available
available
Replenishment Replenished naturally Cannot be replenished
Environmental Environment friendly
Not environment
friendliness except in case of
friendly
biomass
Cost factor Building systems cost is
Production cost is high
high, running cost is
Nature of availability low available
Intermittently Continuously available
Regional restriction Available in certain
No regional restriction
& dependency factor countries

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Introduction to Mechanical Engineering
Fossil Fuels
Coal, oil, and natural gas.
They are called fossil fuels because they were formed over millions and
millions of years - heat from the earth's core, and pressure from rock and
soil on the remains (fossil) of dead plants and animals (including micro-
organisms).
Around 66% of the world's electrical power and 95% of the world's total
energy demands (including heating, transport, power generation and other
uses).

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Introduction to Mechanical Engineering

Coal
Coal is the most abundant fossil fuel on earth.
Combustible black or brownish- black sedimentary rock composed mostly of
carbon and hydrocarbons.
Coal is the major fuel used for thermal power plants to generate steam.
Coal occurs in nature, which was formed by the decay of vegetable matters
buried under the earth millions of years ago under pressure and heat.
Metamorphism.

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Introduction to Mechanical Engineering

Coal and coal mines

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Coal
Lignite, bituminous and Anthracite.

Lignite and bituminous have a lesser percentage of carbon in them and

therefore burn faster.

Anthracite has about 98% of carbon and therefore burns slowly and releases
much less smoke than the other two types.

Coal of all types contain sulphur to some degree, which is the worst of the
pollutants to cause damage to human health and to vegetation.

Despite the above disadvantages, coal remains essential for the industrial
sector like iron and steel making, concrete, and paper industries, etc, driving
locomotives, and for power generation.

The coal mined from the earth is crushed to a fine dust and burnt.

The heat obtained by burning coal is transferred to water to generate steam.

The energy in the steam is used to drive the turbine, which in turn drives
the generator to produce electricity.
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 Introduction to Mechanical Engineering

Advantages of coal
1. Very large amounts of electricity can be generated in one place using coal.

2. A coal-fueled power plant can be built almost anywhere, so long as you can
get large quantities of coal to it.

3. Coal is relatively cheap.

Disadvantages of coal

1. The combustion of coal produces several types of emissions that pollutes the
environment.

2. Mining coal is somewhat difficult and also dangerous.

3. Coal fired power stations requires large area for reserving piles of coal.

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Introduction to Mechanical Engineering

Oil (Petroleum products)

Remains of animals and plants that lived millions of years ago in the sea.
As the years passed, these deposits turned into chemical that are now called
crude oil (hydrocarbons).
Smelly, yellow-to-black liquid and is usually found in underground areas
called reservoirs.
Drill deep holes through which the oil is pumped out.
At oil refineries, the crude oil is heated and split into various types of
products like petrol, diesel fuel, gasoline, aviation fuel, etc., and transported
in huge pipelines and tanker ships to places where it is required.
Oil is particularly used for propelling vehicles like cars, trucks, buses, and
aircrafts. The engine in these vehicles transform the chemical energy stored
in the fuel into heat energy, which in turn is responsible for the movement
of the vehicle.
Oil is also used for residential heating, making products like medicines,
plastics, deodorants, CD's & DVD's, etc.

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Oil (Petroleum products)

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 Introduction to Mechanical Engineering

Oil (Petroleum products)

Some important advantages are as follows:
1. The storage and handling of liquid fuels is much easier than solid and
gaseous fuels.
2. Air required for the complete combustion is less than the solid fuels.
3. Fire control is easy and hence changes in load can be met easily and quickly.
4. There are no requirements of ash handling and disposal.
5. The system is very clean, and hence the labour required is relatively less
compared to the operation with solid fuels.

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Introduction to Mechanical Engineering

Natural Gas
Natural gas is usually found underground near an oil source.

The natural gas is generally obtained from gas wells and petroleum wells.

Major constituent - Methane about 60-65%, and contains small amounts of

other hydrocarbons such as ethane, propane, butane, pentane, and
compounds like carbon dioxide, helium, nitrogen, etc.

Natural gas is the cleanest burning fossil fuel.

When it is burned, it gives off less carbon dioxide than oil or coal, virtually
no sulphur dioxide, and only small amounts of nitrous oxides.

The natural gas is colourless, odourless, and highly toxic.

Its calorific value ranges from 25,000 to 50,000 kJ/Kg-K, in accordance with
the percentage of methane in the gas.

Natural gas is used to produce steel, glass, paper, clothing, brick, electricity,
and as essential raw material for many common products like paints,
fertilizers, plastics, dyes, photographic films, medicines, and explosives.
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Nuclear Fuels
Nuclear fuel is the material that is used in a nuclear reactor to generate
electricity.
Nuclear fuel is used to produce tremendous amount of heat energy which
powers the turbines to generate electricity.
Heat is created when nuclear fuel undergoes nuclear fission or fusion
reaction.
The most common nuclear fuels are uranium-235 (235U) and plutonium-239
(239Pu).
All processes involved in obtaining, refining, and using this fuel make up a
cycle known as the nuclear fuel cycle.

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Introduction to Mechanical Engineering

Fig: Nuclear Energy Conversion

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Advantages of nuclear energy

Produces huge amounts of energy from small amounts of fuel. One ton of
uranium produces more energy than is produced by several million tons of
coal, or several million barrels of oil.
Does not produce smoke or CO2 as is in the case of thermal power plants.
Nuclear power is reliable.

Disadvantages of nuclear energy

Nuclear waste products emit dangerous radiation. Although not much waste
is produced, it is very dangerous. It must be sealed up and buried for many
years to allow the radio activity to die away.
Nuclear power is reliable, but a lot of money has to be spent on safety. If it
does go wrong, a nuclear accident can be a major disaster.

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Introduction to Mechanical Engineering

Hydro Energy
Energy obtained from the flowing water.
In hydroelectric power plants the potential energy of water due to its high
location is converted into electrical energy.
The total power generation capacity of the hydroelectric power plants
depends on the head of water and volume of water flowing towards the
water turbine.

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Hydro Energy

In hydroelectric/hydro power plant a dam is built to collect the rainwater

in a reservoir.
The water from the reservoir is then allowed to flow through penstock
(large pipe) and enter the nozzle where the potential energy is converted
to kinetic energy.
The kinetic energy of water is utilized to run the water turbine, which in
turn drives the generator to produce electricity.
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Advantages of hydel energy

a. Once the dam is built, the energy is virtually free.
b. Working cost of the system is less.
c. No waste or pollution produced.
d. Electricity can be generated constantly.

Disadvantages of hydel energy

a. Dependent on the quantity of water available.
b. Construction of dam is very expensive.
c. Finding a suitable site for the power plant is difficult.

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Solar Energy
Solar energy is the primary source of energy on Earth.
It is the heat energy radiated from the sun.
Solar energy is very large, inexhaustible and a renewable resource.
One square meter of the land exposed to direct sunlight receives an energy
equivalent of about 1 kW of power.
Solar energy can be converted directly or indirectly into other forms of
energy such as heat and electricity by three primary processes: heliothermal,
helioelectrical, and heliochemical process.
Utilization of the solar energy requires collectors.
A solar collector is a device which captures as much sunlight (solar rays) as
possible.
The two types of collectors are Flat plate collectors and Focusing collectors.

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Solar Energy
Flat plate collectors
A flat plate collector is the simplest and the most common type of solar
collector.
In this type, a flat sheet of thermally conductive material (usually black
coated) absorbs the incident solar rays.
The absorbed energy (heat energy) is transferred to cold water or can be
utilized for various applications.
Flat plate collectors are widely used and are preferable for low
temperature applications such as cooking, water heating, drying food
grains and vegetables, heating and cooling buildings, etc.

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Solar Water Heater

The conversion of sun’s radiation into thermal energy (heat energy) is

generally termed as heliothermal process.
Solar water heater is the best example for flat plate collector and is
shown in Figure.
Solar water heater consists of the following components: absorber plate,
transparent cover, water tubes and insulation.
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Solar Water Heater

Absorber plate
It is usually made of copper/aluminium/steel.
It is coated with black material to enhance the absorption of solar radiation.
From the absorbing plates heat is transferred to tubes which carry either
water or air.

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Transparent cover
It is made of a toughened glass, usually 4 mm thick, and helps in reflecting
the incident solar energy back to the absorber plate.
They allow solar energy to reach the absorbing plate while reducing
convection, conduction and reradiation heat losses.

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Water tubes: These are metallic tubes through which water circulates. The
tubes are attached to the absorber plate.
Insulation: It minimizes and protects the absorbing plate from heat losses.
Insulation by means of resin bonded rock wool is provided below the
absorber plate so as to prevent heat losses by conduction.

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Working
Cold water from the overhead tank is made to flow through the water tubes
of the solar heater.
When the sun rises to a certain level, it's energy, passes through the
transparent cover and falls on the absorber plate.
The heat energy absorbed by the absorber plate is transferred to the cold
water flowing through the tubes.
The heated water being lighter than the cold water, rises and flows into the
top of the solar water heater tank.
The cold water from the overhead tank enters the water tubes and the
process repeats. The heated water can be used for various purposes.

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Photovoltaic Cell or Solar Cell
The direct conversion of sun’s radiation into electrical energy (heat energy)
is generally termed as helioelectrical process.
This is achieved with the use of solar cell or photovoltaic cell.
Solar cells are most commonly fabricated from a naturally available
semiconductor silicon, however other materials such as cadmium and
gallium may also be used.
Semiconductors behave like insulator at low temperature and like
conductors above room temperature.
To increase its conductivity, semiconductors are doped with impurities like
boron or aluminum, the resulting which is called p-type semiconductors,
and semiconductors doped with impurities like phosphorous are called n-
type semiconductors.

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Photovoltaic Cell or Solar Cell:

A solar cell is constructed with a sandwich of n-type and p-type wafer

thin semiconductors of silicon.
Sunlight is composed of photons, or particles of solar energy. These
photons contain various amounts of energy corresponding to different
wavelengths of the solar specimen.
When photons strike a photovoltaic cell, they may be reflected, pass
through, or be absorbed.
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Photovoltaic Cell or Solar Cell

Only the absorbed photons provide energy to generate electricity.
When enough sunlight (energy) is absorbed by the material
(semiconductor), electrons are dislodged from the material's atoms.
When the electrons leave their position, holes are formed.

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Photovoltaic Cell or Solar Cell

When many electrons, each carrying a negative charge, travel toward the
front surface of the cell, the resulting imbalance of charge between the
cell's front and back surfaces creates a voltage potential like the negative
and positive terminals of a battery.
When the two surfaces are connected through an external load,
electricity flows.
Solar cells can be used for domestic lighting, street lighting, village
electrification, water pumping, desalination of salt water, railway signals,
powering of remote telecommunication repeater stations, etc.

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Advantages of solar energy

Solar energy is inexhaustible (renewable) and the most abundant source of
energy available freely in nature.
It is an environmental clean source of energy.
Since it is freely available in nature, it can be used as an alternative to high-
cost energy sources.
Since it is an environment clean source of energy, it can be used for
household applications.
Since solar energy can be converted into other forms of energy, it can be
used for a wide range of applications.

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Disadvantages of solar energy

It is a dilute source of energy. Sun does not deliver much energy at one place
at any given time. Hence, large collectors are required to collect the energy
at a useful rate.
Solar energy may be very cheap, but the solar collectors are relatively
expensive and require maintenance to work properly and efficiently.
The availability of solar energy varies with time and weather conditions.
Hence, we cannot depend on it to tap the energy at all times.
The energy collected during the sun shining must be stored for its use
during night times and cloudy conditions. Hence the need for storage,
increases the cost of the system.
Collection of solar energy is a difficult problem. Hence special components
are required to collect the solar energy, and to concentrate it efficiently.

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Wind Energy
Wind energy is the kinetic energy of large masses of air moving over the
earth's surface.
Winds are caused by the uneven heating of the earth's surface by the sun,
the irregularities of the earth's surface, and rotation of the earth.
Hence it can be said that wind energy is a form of solar energy.
The kinetic energy of wind can be converted into mechanical work (rotation
of shaft) by a wind turbine.
The mechanical power thus obtained can be used for specific tasks such as
grinding food grains, pumping underground water, generate electricity, etc.

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Wind Energy
A wind turbine consists of specially designed
blades that are connected to a low-speed shaft.
A gear box connects the low-speed shaft to the
high-speed generator shaft to increase the
rotational speeds from about 30-60 rotations
per minute (rpm) to about 1000-1800 rpm to
produce electricity.
In operation, the blades of the windmill rotate
due to the kinetic energy of the flow of wind.
This makes the shaft to rotate which in turn
drives the generator to produce electricity.
Since wind speed increases with height, the
blades are mounted high above the ground
level by means of a tower.
Tamilnadu, Andhra Pradesh, Kerala,
Karnataka and coastal areas of Gujarat and
Maharashtra have found to be suitable for
generating power using wind energy.

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Advantages of wind energy

Inexhaustible (Renewable) source of energy.
Freely available in nature and environment friendly.
Since it is freely available in nature, it can be used as an alternative to high-
cost energy sources
Cheap sources for power generation.
Good method of supplying energy to remote areas.

Disadvantages of wind energy

Wind is not always predictable, and hence cannot depend for continuous
power production
Wind is always not available.
Windmills cannot be located at all places.
Noisy in operation

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The world’s largest turbine, GE’s Haliade-X offshore wind turbine, has blades up
to (107 meters (351 feet) long!

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Department of Mechanical Engineering, MCE, Hassan 82

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Biofuels
Biofuel is a type of renewable energy source derived from microbial, plant,
or animal materials.
Biofuels can be solid, liquid, or gaseous.
They are most useful in the latter two forms as this makes it easier to
transport, deliver, and burn cleanly.
Biofuel is a fuel that is produced over a short time span from biomass,
rather than by the very slow natural processes involved in the formation of
fossil fuels, such as oil.
Biofuels are produced from sugar crops, starch crops, oilseed crops and
animal waste.
Examples of biofuels include ethanol (often made from corn in the United
States and sugarcane in Brazil), biodiesel (sourced from vegetable oils and
liquid animal fats), green diesel (derived from algae and other plant
sources), and biogas (methane derived from animal manure and other
digested organic material).

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Applications of Biofuels
Biogas is cheap and sustainable fuel used in lighting, cooking or generating
electricity.
Biodiesel finds its use in automotive industry mainly in cars and trucks.
Small engines are seen in lawn movers and chain saw.
The marine industry finds application of biofuel in suitable blend mixtures
to be used in boats and ships.

Problems Associated with Biofuels:

Biofuel is compatible with current engines but with certain issues. The most
important of these are
Biodiesel exhibits cold weather problems.
Some types of biodiesels have exhibited storage instability that could lead to
engine problems.
Diesel additives may not provide the same benefits when used with
biodiesel.
Sometimes, vegetable oils create adverse effects on engine components due
to their volatility, molecular structure, and high viscosity.
Department of Mechanical Engineering, MCE, Hassan 85
Introduction to Mechanical Engineering
Engineering Materials
• Engineering materials are defined as solid substances which are
manufactured and used for various engineering applications.
• There are various materials available and the choice of a particular material
for a specific application depends on the set of properties possessed by the
materials.

Department of Mechanical Engineering, MCE, Hassan 86 86

Introduction to Mechanical Engineering

Department of Mechanical Engineering, MCE, Hassan 87

Introduction to Mechanical Engineering

Metals and Their Alloys

• A metal is a material, an element, compound or alloy that is typically hard
when in the solid state, opaque and shiny
• Metals are generally malleable and ductile

Department of Mechanical Engineering, MCE, Hassan 88

Introduction to Mechanical Engineering

Classification of Ferrous Metals

Pig Iron
• It is the first stage of iron directly extracted from the ore through blast
furnace. It Contain high percentage of carbon and other impurities.
• Properties: High hardness and Vey brittle
• Applications: It is used in making wrought iron, cast iron and steel

Department of Mechanical Engineering, MCE, Hassan 89

Introduction to Mechanical Engineering

Wrought iron
• Wrought iron is an iron alloy with a very low carbon content
• Properties: Low carbon content, Soft, Highly Ductile in nature, High
toughness, Good machinability, Corrosion resistance, High elasticity
• Applications: Due to corrosion resistance, it is used in making steam and
water pipes. Decorative applications like fences, gates and railings, balconies,
bars, engine bolts, rivets, railway couplings, chain links and crane hooks.

Department of Mechanical Engineering, MCE, Hassan 90

Introduction to Mechanical Engineering

Cast Iron
• Is a ferrous material that is produced when pig iron is remelted in a cupola
furnace and poured into mould in order to make castings
• Properties: Very strong but brittle, Low melting point, Good fluidity,
Castability, Good machinability, wear resistance
• Applications: Manufacture of machine frames, columns, beds and plates,
housing, flywheels, manhole covers, engine block, cylinder head, gearbox
case, machine parts etc.

Department of Mechanical Engineering, MCE, Hassan 91

Introduction to Mechanical Engineering

Grey Cast Iron

• It is produced when the molten pig iron in the mould is allowed to cool and
solidify slowly. Carbon here is mainly in the form of graphite.
• Properties: Good castability, High fluidity, easy Machinability, high strength
and ductility under compressive loads. It is named as Grey cast iron because
of its freshly fractured surface has a grey appearance.
• Applications: Base structures of machinery, Automotive engine blocks,
gears, flywheels, brake discs and drums and machine bases.
• Others – white and malleable cast iron

Department of Mechanical Engineering, MCE, Hassan 92

Introduction to Mechanical Engineering

Steel
• Steel is an alloy of iron and carbon with carbon content being less than 2% .
In addition various alloying elements like sulphur, phosphorous, manganese,
nickel, chromium, copper etc., in small proportions.
• Types: Carbon steel, alloy steel and tool steel
Carbon Steel
• Is a kind of steel in which the main alloying constituent is carbon in the
range of 0.12-2%.
• This tiny amount of carbon produces a material that exhibits great strength,
hardness. Other elements present in small proportions are sulphur,
phosphorous, manganese and magnesium
• It is classified as
• Low Carbon Steel
• Medium Carbon Steel
• High Carbon Steel

Department of Mechanical Engineering, MCE, Hassan 93

Introduction to Mechanical Engineering

Low Carbon Steel

• It is also called as Mild steel and the most common type of carbon steel. It
contain 0.03-0.25% off carbon and rest is iron
• Properties: It is soft, ductile and it has good machinability, good weldability,
good toughness, good impact resistance.
• Applications: It finds applications in nails, rivets, bolts, nuts, beams, boiler
plates, shafts, gears and axles.

Department of Mechanical Engineering, MCE, Hassan 94

Introduction to Mechanical Engineering
Medium Carbon Steel
• It has 0.25-0.59% of carbon and rest is iron.
• Properties: It has properties like good toughness, high hardness, high
tensile strength, good bending strength, wear resistance and good
machinability.
• Applications: It is used in transmission shafts, axles, gears, connecting rods,
couplings and in spring manufacturing.

Department of Mechanical Engineering, MCE, Hassan 95

Introduction to Mechanical Engineering

High Carbon Steel

• It has 0.6 – 1.5% of carbon and rest iron.
• Properties: It has good strength and wear resistance, very ductile, low
impact strength.
• Applications: It is used in hammers, Chisels, Screws, Punches, Hacksaw
blades, Drills, Leaf spring, ball bearings, milling s-cutters.

Department of Mechanical Engineering, MCE, Hassan 96

Introduction to Mechanical Engineering
Alloy Steel
• An alloy can be defined as a homogeneous mixture of two or more metals.
Alloy steel include iron and carbon.
• These steels are produced by adding other than carbon in calculated
amounts in order to provide specific properties.
• Principle alloying elements are chromium, nickel, manganese.
• Alloying elements are added for properties such as
• Improved machinability, weldability and castability
Improved strength and ductility Improved fatigue and
corrosion resistance
• Common types of alloy steels are
• Chromium steel
• Nickel steel
• Manganese Steels

Department of Mechanical Engineering, MCE, Hassan 97

Introduction to Mechanical Engineering

Applications of stainless, chromium and nickel steel

Department of Mechanical Engineering, MCE, Hassan 98

Introduction to Mechanical Engineering

Classification of Non - Ferrous Metals

Aluminium
• It is one of the widely used metal in recent years, which has replaced iron
and steel because its special properties like light weight, non-corrosive, it
is silvery white, soft, ductile material.
• It is extracted from Bauxite
• The mechanical properties can be improved by mixing aluminium with
silica, copper, zinc
• Properties: Light weight, high ductility, good electrical and thermal
conductivity, good resistance to corrosion
• Applications: aircraft parts, automobile parts, cooking utensils, cables,
induction motors

Department of Mechanical Engineering, MCE, Hassan 99

Introduction to Mechanical Engineering

Alloys of Aluminium
• Duralumin - 92% Aluminium, 3.5-4.5 Copper, 0.4-0.7 % Magnesium, 0.4-7%
Manganese
• Magnalumin - 95% Aluminium, 5% Magnesium
• Yttrium-Alloy - 93% of aluminium, 4% copper, 2% nickel and 1%
magnesium

Department of Mechanical Engineering, MCE, Hassan 100

Introduction to Mechanical Engineering
Copper
• Reddish brown colour, extracted from PYRITE
• Properties: It is soft, malleable, ductile, light weight, high thermal
conductivity, good corrosion resistance, good electrical and thermal
conductivity
• Applications: door knobs, electrical wires, alloy of brass and bronze, tubes
in refrigerators and air conditioners
• Other – tin, lead, zinc and their alloys

Department of Mechanical Engineering, MCE, Hassan 101

Polymers
Polymers are materials that consist of molecules formed by
long chains of repeating units. They may be natural or
synthetic.
Many useful engineering materials are polymers, such as
plastics, rubbers, fibers, adhesives, and coatings.
Polymers are classified as thermoplastic polymers,
thermosetting polymers (thermosets), and elastomers.

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Thermoplastic Polymers
Classification of thermoplastics and thermosets is based on
their response to heat.
If heat is applied to a thermoplastic, it will soften and melt.
Once it is cooled, it will return to solid form.
They are therefore very well suited to injection molding.

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Thermosetting Polymers
Thermosets are typically heated during initial processing,
after which they become permanently hard.
Thermosets will not melt upon reheating.
Thermosets typically have greater hardness and strength
than thermoplastics.

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Elastomers
Elastomers are highly elastic polymers with mechanical properties
similar to rubber.
Elastomers are commonly used for seals, adhesives, hoses, belts, and
other flexible parts.
The strength and stiffness of rubber can be increased through a process
called vulcanization, which involves adding sulfur and subjecting the
material to high temperature and pressure.

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Ceramics

Ceramics are solid compounds that may consist of metallic or non-metallic elements.

The primary classifications of ceramics include glass, cement, clay products,

refractories, and abrasives.

Ceramics generally have excellent corrosion and wear resistance, high melting
temperature, high stiffness, and low electrical and thermal conductivity.

Ceramics are also very brittle materials.

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Glass
Glasses are common materials and are seen in applications including
windows, lenses, and containers.
Glasses are amorphous, whereas the other ceramics are mainly
crystalline.
Primary advantages of glasses include transparency and ease of
fabrication.
The base element of most glasses is silica, and other components can be
added to modify its properties.

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Clay
Clay is a very common ceramic material.
It can be mixed with water, shaped, and then hardened through firing at
high temperature.
The two primary classifications of clay products include structural clay
products and whitewares.
Structural clay products see applications including bricks, tiles, and
piping.
White wares see applications including pottery and plumbing fixtures.

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Refractories
Refractory ceramics can withstand high temperatures and extreme
environments.
They can also provide thermal insulation.
Brick is the most common refractory ceramic.

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Abrasives
Abrasive ceramics are hard materials that are used to cut, grind, and
wear away other softer materials.
Typical properties of abrasives include high hardness, wear resistance,
and temperature resistance.
Abrasives can either be bonded to a surface (e.g. grinding wheels and
sandpaper) or can be used as loose grains (e.g. sandblasting).
Common abrasives include cemented carbide, silicon carbide, tungsten
carbide, aluminum oxide, and silica sand.
Diamond is also an excellent abrasive, but it is expensive.

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 What are Composite Materials?
❖ Composite material is a structural material that
consists of two or more combined constituents which
are combined at macroscopic level and are not soluble
in each other.
❖ One of its constituents is called the reinforcing phase
and the other one, in which the reinforcing phase
material is embedded, is called the matrix.
❖ The reinforcing phase material may be in the form of
fibers, particles, or flakes (e.g. Glass fibers).
❖ The matrix phase materials are generally continuous
(e.g. Epoxy resin).
❖ The matrix phase is light but weak.
❖ The reinforcing phase is strong and hard and may not
be light in weight.
 Advantages of Composites

❑ Composites are engineered materials. We can engineer

them specifically to meet our needs on a case‐to‐case basis.
❑ In general, following properties can be improved by using
composite materials.
✔ Strength
✔ Modulus
✔ Weight
✔ Electrical conductivity
✔ Thermal conductivity
✔ Fatigue
✔ Behavior at extreme temps.
✔ Acoustical insulation
✔ Vibration damping
✔ Aesthetics
✔ Resistance to wear
✔ Resistance to corrosion
 Limitations of Composites

✔ Costly
✔ Difficult to fabricate
✔ Sensitivity to temperature
✔ Moisture effects
 Applications of Composites

Automotive industry: Lighter, stronger, wear resistance,

rust‐free, aesthetics
– Car body
– Brake pads
– Drive shafts
– Fuel tanks
– Hoods
– Spoilers
Aerospace: Lighter, stronger, temperature resistance,
smart structures, wear resistance
– Aircraft: Nose, doors, struts, trunnion, fairings, cowlings,
ailerons, outboard and inboard flaps, stabilizers,
elevators, rudders, fin tips, spoilers, edges
– Rockets & missiles: Nose, body, pressure tanks, frame,
fuel tanks, turbo‐motor stators, etc.
– Satellites: Antennae, frames, structural parts
Sports: Lighter, stronger, toughness, better aesthetics,
higher damping properties
– Tennis
– Bicycles
– Badminton
– Boats
– Hockey
– Golfing
– Motorcycles …
Transportation & Infrastructure: Lighter, stronger,
toughness, damping
– Railway coaches
– Bridges
– Ships and boats
– Dams
– Truck bodies and floors
– RV bodies
Other industry sectors
Biomedical industry
Consumer goods
Agricultural equipment
Heavy machinery
Computers
Healthcare