76
4.1 AUTO ENGINE - I
L T P
3 - 3
RATIONALE
Engine forms the base of automobile engineering. Since the scope of automobile engines
is very wide, it has been divided in two subjects i.e. Auto Engine-I and Auto Engine-II.
Auto Engine-I mainly deals with constructional details and various systems of petrol
engine like fuel, carburetor and MPFI ignition, cooling, lubrication system and
manifolds.
DETAILED CONTENTS
1. Introduction
Concept of internal and external combustion engine and their comparison,
classification of IC engine as per stroke, cycle of operation. Types of fuels
used, method of air charging, types of ignition, types of cooling, cylinder
arrangement, engine location. Applications of IC engines, two stroke, four
stroke of S.I. and C.I. engine
Engine performance parameters (definitions only), BHP, IHP, FHP,
indicated thermal efficiency, mechanical efficiency, volumetric efficiency,
relative efficiency, mean effective pressure and specific fuel consumption.
(10 hrs)
2. Construction Details
Specifications, functions, working and materials of components – cylinder
block, cylinder head, cylinder liner, piston, piston rings and wrist pin,
connecting rod, crank-shaft, cam shaft, bearings, valves and valve
actuating mechanism, fly wheel and dampers.
Nomenclature of cylinder bore, piston area, stroke, dead centres (top and
bottom), swept volume, clearance volume, compression ratio
(8 hrs)
3. Fuel Supply System
Fuel supply circuits in petrol engine, function of various components in the
circuit, gravity, vacuum and pump feed systems, AC mechanical and electrical
fuel feed pump, fuel filters, fuel gauges – balanced coil and bi-metallic type.
(6 hrs)
77
4. Carburation
Theory of carburation, air fuel ratio required under various conditions of
operation of engine. Important circuits in carburetors – starting, idling, low
speed accelerating, economy and full power circuits. Automatic chokes,
description of solax and amal carburetors.
MPFI – Description and working of multipoint fuel injection. Advantages
and disadvantages of M.P.F.I
(8 hrs)
5. Ignition System
Phenomenon of carburation in petrol engine, type of spark ignition system,
battery/coil and magneto ignition system. Distributor: its function, layout and
drive. Automatic spark advance methods. C.B. point gap, spark plug gap
adjustment. Ignition timing. Electronic ignition system.
(4 hrs)
6. Cooling System
Necessity of cooling, types, direct and indirect, air cooling fins, blowers
application, indirect or coolant cooling, pump circulation system, water jacket,
water pump fan and its drive. Radiator and its types. Thermostat for
temperature control, temperature gauges, pressurized cap, anti-freeze
solutions, scale and corrosion.
(4 hrs)
7. Lubrication Systems
Various lubrication systems – splash, pressure and combined splash of
pressure lubrication, oil pumps, oil lines, filters, coolers, crank case
ventilation. Requirements of engine lubrication oils, their specifications, oil
consumption and additives for lubricants.
(4 hrs)
8. Air Supply/Intake and Exhaust system
Inlet and exhaust manifold, consideration for good manifold design, materials.
Various types of air cleaners – dry and wet, centrifugal. Exhaust silencers,
different types, valve timing diagrams
(4 hrs)
78
LIST OF PRACTICALS
1. Servicing of lubrication system – flushing crankcase, cleaning and replacing oil,
filter elements.
2. Servicing of fuel system – petrol feed system, cleaning, flushing fuel tank,
changing of fuel filters.
3. Servicing of feed pump, mechanical, electrical pump and testing.
4. Servicing of air cleaning.
5. Servicing of carburetor, cleaning and adjustment.
6. Setting of fuel injection pump timing of a diesel engine.
7. Overhauling of fuel injector and pump.
8. Servicing of valves and vale mechanism – replacement of valve, valve seats and
valve seats, checking and replacement of defective springs, facing of valves,
tappet and rocker arm, adjusting valve tappets.
9. Dismantling and assembling water pumps. Back – flushing of cooling
system/radiator.
10. Engine tune up
LIST OF BOOKS
1. Automobile Engineering by Dr. Kirpal Singh, Standard Publications.
2. Automobile Engineering by RB Gupta.
3. Automobile Engineering by Chitkara.
79
4.2 MATERIALS AND METALLURGY
L T P
3 - 2
RATIONALE
Materials play an important role in the construction and manufacturing of
equipment/tools. Right selection of materials add to the economy, working and life of
machinery. A diploma holder must be conversant with the properties, uses, availability
and costs of materials used for construction/fabrication to enable him to perform his
functions confidently. The subject of Materials and Metallurgy has been designed to
cover the above aspects.
DETAILED CONTENTS
1. Importance of Materials
Classification: Metals and non-metals, Ferrous and non-ferrous metals
and their alloys
Names of common metals, their alloys and non-metals used in
Industry
Properties of metals and alloys
Physical properties - Appearance, luster, colour, density and melting
point
Mechanical Properties: Strength, stiffness, elasticity, plasticity,
toughness, ductility, malleability, brittleness, hardness, fatigue and
creep.
Thermal and electrical conductivity
Corrosion, causes, effects and prevention.
(4 hrs)
2. Metallurgical Considerations
Solidification of metals form liquid to solid state of pure metals, cooling
curves of pure metals, dendritic solidification, crystal formation, types of
crystal structure. Phase diagram of:
(i) Solid-state solubility.
(ii) Partial solubility.
(iii) Nil solubility i.e. eutectic solution (Binary only). Effects of all
alloying elements on engineering materials. Effect of grain size
on mechanical properties.
(6 hrs)
80
3. Ferrous Metals and Alloys
Flow diagram for the production of ferrous metals from their ores,
constituents of iron, iron carbon diagram.
Classification, composition and uses of cast iron and plain carbon
steels. IS, BS and SAE Grades
Effect of alloying elements such as Aluminium, chromium, Nickel,
Cobalt, Manganese, Molybdenum, tungsten, Vanadium, Silicon,
Sulphur and Phosphorous on steels.
Composition, properties, grades and uses of special steels such as High
speed steel, Stainless steels, Silicon steels, Heat resistant steels, Spring
steel.
Heat Treatment: Iron-carbon diagram, objectives and practical aspects
of heat treatment. Brief description and uses with examples of
principal heat treatment processes, Annealing, Normalizing,
Tempering, Hardening, Carburising, Nitriding and Cyaniding and
applications. Examples in heat-treating engineering components time,
temperature transformation curve.
(12 hrs)
4. Non-ferrous Metals and Alloys
Copper: Properties and uses
Composition, properties and uses of copper alloys.
Brasses: Cartridge brass, Nickel silver.
Bronzes: Phosphor bronze, Al-bronze, Mn-bronze, and Gun metal.
Properties and uses of Aluminium.
Composition, properties and uses of Al-alloys e.g., Duralumin, Yellow
metal, Magnalium and Hindalium
Properties and uses of alloys of lead, tin and magnesium.
Bearing Metals: Requisite qualities. Composition, properties and uses
of white metal bearing, copper based bearing metals. Aluminium
based bearing metals. Use of nylon/PTFE for bushes/bearings, bimetallic
and tri-metallic bushes
(12 hrs)
81
5. Identification and Examination of Metals and Alloys
Identification tests - Appearance, sound, filing, weight, magnetic, spark,
bend and microstructure. Different types of etchants for preparation of
surface structure.
(1 hrs)
6. Other Important Materials
Plastics: Definition, classification of plastics, fibre glass, reinforced
plastics. Major applications of various plastics and their uses and
grades.
Composite materials.
Heat insulating materials: Properties and uses of asbestos, glass wool,
thermocole, cork, mica.
Electrical insulating materials. Properties and uses of china clay,
leather, bakelite, ebonite, glass wool, rubber, felt.
Sound insulating materials: Cork, fibre boards.
Fabrication materials: Wood, plywood, rubber – natural and synthetic,
Glass – plate glass, toughened glass, safety glass.
Refractory materials: General characteristics and uses of dolomite,
ceramics.
Protective coating materials: Paints, primers, varnishes, enamels,
putti, electroplating materials, rubasil, teflon coating.
Sealant and adhesives – Application and availability of sealant and
adhesives for industrial user.
(10 hrs)
7. Selection, specifications and commercial availability of materials
Practical considerations for selection of material for different purposes
ISO/Bureau of Indian standard specifications for metals, non-metals,
various components and materials.
(3 hrs)
82
LIST OF PRACTICALS
1. Classification of about 25 specimen of materials/parts in material lab, identify and
indicate the type of materials with respect to their properties
2. Study of metallurgical microscope.
3. To prepare microscopic structure for examination and to examine the micro
structure of specimens of various metals and alloys.
4. Study of heat treatment furnaces.
5. To study the effects of heat treatments processes on the following materials:
(i) Low carbon steel
(ii) Mild steel
(iii) High Carbon Steel
RECOMMENDED BOOKS
1. Material Science by GBS Narang, Khanna Publishers, New Delhi.
2. Material Science and Metallurgy by RB Choudary, Khanna Publishers, New
Delhi.
3. Material Science by RK Rajput; SK Kataria and Sons, Delhi.
4. Materials and Matallurgy by D.S. Nutt. SK Kataria and Sons, Delhi.
83
4.3 CHASSIS, BODY AND TRANSMISSION - I
L T P
3 - 3
RATIONALE
Chassis, body and transmission forms the core of automobile engineering. The subject
focuses at imparting knowledge and skills regarding chassis and body, viz. clutch system,
transmission system, drive system, steering mechanism, braking system, wheels and
tyres.
DETAILED CONTENTS
1. Chassis and Body
Classification of vehicles, layout of conventional type of chassis, function and
arrangement of major assemblies. Alternating arrangement used such as engine
position, drive types, their merits and demerits. Constructional details of car
body. Materials used for chassis frames, body components, interior body
dressing components, body upholstery, body streamlining, protective coatings
and body air-conditioning, types of frame and body, cross members, brackets,
materials for frame.
(6 hrs)
2. Clutch
Necessity, function and requirements of clutch, types of clutch - single plate,
multiplate clutch, wet and dry clutch, clutch plate and lining material
(5 hrs)
3. Transmission
Necessity, function, types and working of transmission – sliding, constant
mesh, synchromesh
(6 hrs)
4. Driveline
Propeller shaft - function, construction details. Universal joints - functions and
types. Constant velocity joints. Types of final drive – hotchkiss drive, torque
tube drive. Differential – principle, functions and its working, rear axles – semi
floating, fully floating, three quarter floating. Common faults and remedies
(8 hrs)
84
5. Steering
Types of front axles and their constructional details. Steering mechanism,
function Ackerman’s Principle of steering , working and constructional details
of steering gear, steering linkages, front and geometry-castor, camber, steering
axis inclination, toe in and toe out. Cornering force, cornering power and selfrighting
torque, over steering and under steering.
(8 hrs)
6. Braking System
Purpose of brakes, layout of hydraulic and mechanical braking system,
components. Principle of hydraulic brakes, braking action, master cylinder,
wheel cylinder, leading and trailing shoes, self adjusting and self releasing
action, its dissipation, antilock and antiskid devices, pedal travel, brake
enclosures, heat generation, its dissipation, and operating temperature, brake
drum and their material, lining materials, lining thickness and lining area, brake
shoes, shoe clearance, split brakes, hand brakes, brake fluids, disc brakes, brake
adjusters
(8 hrs)
7. Wheel and Tyres
Wheels – types, constructional details, specifications. Tyres - classification and
purpose. Types, construction of pneumatic tyres, details of carcass of various
types, comparison of cross-ply and radial-ply tyres, causes of excessive tyre
wear, effects of different conditions of vehicle stability. Tyre care and
maintenance, tubes and their types. Static and dynamic balance, retreading of
tyres, tubeless tyres.
(7 hrs)
LIST OF PRACTICALS
1. Identify and service single and multiplate clutch.
2. Servicing of steering system – steering gear boxes, correction and adjustment of free
play.
3. Servicing/overhauling of brakes – mechanical, hydraulic, brake adjustment and
bleeding.
4. Checking and adjustment of Camber, Caster, toe-in, toe-out, king pin inclination.
5. Removing dents and minor repair, body trimming and painting.
6. Wheel balancing – static and dynamic.
7. Practice in brake shoe riveting, de-riveting, aligning the shoes and adjustment of
brakes.
8. Servicing/overhauling of gear box.
85
RECOMMENDED BOOKS
1. Automobile Engineering, Vol. I by Dr. Kirpal Singh, Standard Publishers
2. Automotive Chassis and Body by PL Kohli
3. Automobile Engineering by GBS Narang, Khanna Publishers, Delhi
4. Automobile Engineering by CP Nakra
86
4.4 MANUFACTURING TECHNOLOGY - II
L T P
3 - 4
RATIONALE
Knowledge in various machining operations viz. drilling, boring, milling, planning and
grindin processes, finishing operations, gear production, CNC machining, bending
forming and welding processes is very essential for the diploma holders. Hence this
subject.
DETAILED CONTENTS
1. Drilling and Boring
Introduction, Types of drills, types of drilling machines i.e. portable, bench
type, piller and radial, drilling speeds and feeds, drill chucks and other
accessories (jigs etc.) used in drilling machines, reaming, introduction to
boring, types of boring machines – horizontal and vertical, specifications,
boring bar and boring heads
(8 hrs)
2. Machining Processes
Milling – Types of milling machines and their operations, speeds and
feeds, indexing (simple and compound), types of milling cutters
Planing machines and their operation
Grinding – cylindrical, centreless and surface grinding machines, types
of grinding wheels, specifications, grades and their selection, balancing
of grinding wheels and their storage
(12 hrs)
3. Finishing Operations
Lapping, honing, superfinishing operations and their applications, types of
abrasives used and their selection
(4 hrs)
4. Gear Production
Gear cutting and gear shaving machines, gear cutters and coolants
(4 hrs)
5. CNC Machines
Introduction to CNC control systems, advantages, productivity, accuracy
and cost
(4 hrs)
87
6. Bending and Forming
Description of press brakes, bending dies, forming machines
(4 hrs)
7. Welding
Introduction, types of welding (gauge welding, arc welding, resistance
welding), butt welding, flash, projection, seam and spot welding.
Selection of electrodes, filter metals, types of welding defects and their
remedies, soldering and brazing – processes and applications
Special welding processes for stainless steel and aluminium
(10 hrs)
8. Types of Coolants and Lubricants for various machining processes
(2 hrs)
LIST OF PRACTICALS
1. Introduction to drilling and boring machines, an exercise of simple drilling
and boring operation, selection of speeds and feeds, use of jigs and fixtures
and coolant.
2. Simple exercises on shaper
3. Practice on horizontal and vertical milling machines, work holding devices
and types of milling cutters
4. Practice on cylindrical and centreless grinding machine, selection, dressing
and storage of grinding machines. Use of lubricants
5. Practice on honing machines with selection of honing sticks, honing and
finish pattern in the bore. Bore geometry measurement
6. Observe working of CNC machines including setting of cutting parameters
and dimensions and loading of tools, repeatability of operation and
adjustment for wear allowances
7. Visit to industry (sheet metal shoos) to observe bending and forming
operation and use of dies
8. Use of appropriate coolant and lubricants for all machining operation in the
workshop and during Industrial visits.
RECOMMENDED BOOKS
1. Workshop Technology by BS Raghuwanshi, Dhanpat Rai & Sons, Delhi.
2. Workshop Technology Vol. – I, II & III by Chapman, Standard Publishers
Distributors, New Delhi.
3. Workshop Practice by RK Singhal, SK Kataria & Sons, New Delhi.
4. Production Technology by HMT, Tata McGraw Hill, New Delhi.
5. Elements of Workshop Technology by SK Chaudhary & Hazra, Asia Publishing
House.
88
4.5 AUTO ENGINEERING DRAWING - II
L T P
- - 6
RATIONALE
An automobile engineering diploma holder, irrespective of his field of operation in an
industry or transport undertaking, is expected to possess a thorough understanding of
engineering drawing, which includes clear spatial visualization of the subject and the
proficiency in reading and interpreting a wide variety of production drawings and
maintenance drawings. Besides this, he/she is also expected to have a certain degree of
drafting skills depending upon his job functions to perform his day-to-day activities e.g.
communicating and discussing the ideas with his superiors and passing on instructions to
his subordinates in an unambiguous way. Hence this subject. The teachers are
recommended to give more emphasis to the students by showing them automobile
components.
Note:
All assembly drawings to be made to scale except wherever mentioned otherwise
specifically
Candidates may be asked to show specific sections of the component/assembly
50% of the drawings shall also be made by AutoCAD for which no question shall be
set in the written paper
AutoCAD component shall be included in the practical/viva voce examination
DETAILED CONTENTS
1. Engine Components
AC fuel feed pumps (assembly)
Fuel injection pump (jerk type) (assembly)
Fuel injector (assembly
Overhead and side valve mechanism (free hand)
Water cooling system (free hand)
(24 hrs)
2. Chassis Components
Leaf spring suspension (assembly)
Shock absorber (assembly)
Internal expanding shoe brake (assembly)
Master cylinder (assembly)
Wheel cylinder (assembly)
Independent suspension system (free hand)
Brake drum (assembly)
Air assisted hydraulic brake system (free hand)
(33 hrs)
89
3. Auto Electrical Circuits (free hand sketches)
Electrical circuit of battery and magneto ignition system
Automobile gauges and meters circuit diagram
Automobile lighting and signaling circuits
Complete wiring diagram of a car
(12 hrs)
4. Transmission
Single plate clutch (assembly)
Gear box (free hand sketch)
Rear axle (fully floating) (free hand)
(18 hrs)
5. Garage
Free hand sketch of a bus
Free hand layout of a garage having a fleet of 100 vehicles
(9 hrs)
Note: 50% of drawings to be made using AutoCAD
RECOMMENDED BOOKS
1. Automobile Engineering Drawings by RB Gupta.
2. Machine drawings by PS Gill.
3. Machine Drawings by Laxmi Narayan and Mathur.
90
4.6 COMPUTER APPLICATIONS IN MECHANICAL ENGINEERING
L T P
- - 4
RATIONALE
Today age is computer age. Most of our daily activities are being influenced by the use
of computers. While in areas like science and technology, improvements cannot be
achieved without computers. It has become necessary for each and everyone of us to
have a basic knowledge of application of computers. PowerPoint is a feature packed
presentation programme whereas access is database management systems. Programming
is backbone for preparing various technological projects, which can be achieved by C++
language – most versatile one in today’s scenario. This subject is being offered to
acquaint the students about MS PowerPoint, MS Access and Programming using C++
language.
DETAILED CONTENT
1. Computer Application Overview
(3 hrs)
Commercial and business data processing applications
Engineering computation
2. MS PowerPoint
(15 hrs)
2.1 Introduction
Elements of power point package- templates, wizards, views, color schemes
Starting PowerPoint
Exploring PowerPoint menus
Starting a new slide
Adding title, text and art
Moving text area and resizing text box
Starting a slide show
Saving a presentation
Printing slides
Inserting and deleting slides
Closing a presentation
Exercise for making a presentation and slide show
2.2 Views
PowerPoint views – slide view, outline view, slide sorter view, notes view, slide
show view, slide setup
Zoom in, zoom out
Exercises on various views of presentation
91
2.3 Formatting and Enhancing text
Formatting
Changing format with a new layout
Alignment of text and text spacing
Enhancing text formatting – use of bullets, changing text font and size
Selecting text style and color
Applying design template
Closing and applying the transition
Spell checking
To set header and footer
Exercise on formatting text and applying design template.
2.4 Slide with graphs
Creating a graph
Adding graphic objects
Adding clipart pictures
Adding movies and sounds
Adding multimedia to presentation
Inserting excel worksheet or word table
Exercise on inserting graphs, tables, movies and clipart.
3 MS - Access
(16 hrs)
3.1 Introduction to Microsoft access
Components of access
3.2 Table creating
Starting access, creating tables, tool bars and views of tables
Editing the design and contents of the table
Creating relationship between tables
Adding OLE objects to a table
Use of import and export facility
Exercise on table creating
3.3 Query Handling
Creating a new query, use of criteria, expressions and operation
Editing a query, print a query
Exercise on creating and editing query
3.4 Form designing
Introduction, creating a form, modify a form design, designing a form using
design view.
Sub – forms, printing the forms, exercise on form designing.
92
3.5 Report designing
Creating a report, managing the different controls of the records, saving and
printing the report, use of graphs in reports
Exercise on report designing
4 Programming fundamentals
(6 hrs)
Algorithm, pseudo language, flow charts: advantages and disadvantages
Decision table – type, advantages and disadvantages
Structured programming: structuring the control flow, modular programming
Exercise on making algorithm and flow charts.
5 C++ programming
(24 hrs)
5.1 Fundamentals
Introduction, oop, character set, C++ tokens, keywords, identifiers, constants,
basic data type, declaration of variables, defining symbolic constants, assignment
statement, comments in a programme, structure of C++ programme, output using
COUT, output using CIN, manipulators.
5.2 Operators and Expressions
Arithmetic operators, relational operators, logical operators, shorthand assignment
operator, increment and decrement operators, conditional operators, bit wise
operators, precedence in C++ operators, casting of data, standard mathematical
functions.
5.3 Control structures
IF statements, IF---ELSE statements, nested IF statements, switch statements, Go
To statements, repetitive structures, while statements, do statement, for loop,
break statement, continue statement, nested loops.
5.4 Programs
Write a program to check if a number is even or odd.
Write a program to find the smallest of 3 numbers.
Write a program to find largest of 4 numbers
Write a program to find the roots of quadratic equation.
Write a program to find the sum of the first N natural numbers using a for - do
loops.
Write a program that reads in N numbers and finds the smallest number among
them.
Write a program to find the sum of squares of the digits of a number.
6. Demonstration of CNC machine
RECOMMENDED BOOKS
1. MS Office 2000 for everyone by Sanjay Saxena; Vikas Publishing House Pvt. Ltd.
2. MS Office 2000 by Steve Hill; BPB Publications.
3. Programming in C++ by B. Subharamanayam.
4. Programming in C by Abdul Khader; Ajanata Publications
93
INDUSTRIAL TRAINING
Industrial Training aims at exposing the students to field practices, size and scale of
operations and work culture at practical sites. For this purpose, students at the end of
fourth semester, are required to be sent for a period of 4 weeks at different work sites.
Each student is supposed to study the material and technology used at site and prepares a
detailed project report of the observation of processes seen by him/her. These students
should be supervised and guided by respective subject teachers. Each teacher may guide a
group of four to five students.
The teacher along with field supervisors will conduct performance assessment of
students. The components of evaluation will include the following.
- Punctuality and regularity 15%
- Initiative in learning new things 15%
- Relationship with workers 15%
- Industrial training report 55%
4.1 AUTO ENGINE - I
L T P
3 - 3
RATIONALE
Engine forms the base of automobile engineering. Since the scope of automobile engines
is very wide, it has been divided in two subjects i.e. Auto Engine-I and Auto Engine-II.
Auto Engine-I mainly deals with constructional details and various systems of petrol
engine like fuel, carburetor and MPFI ignition, cooling, lubrication system and
manifolds.
DETAILED CONTENTS
1. Introduction
Concept of internal and external combustion engine and their comparison,
classification of IC engine as per stroke, cycle of operation. Types of fuels
used, method of air charging, types of ignition, types of cooling, cylinder
arrangement, engine location. Applications of IC engines, two stroke, four
stroke of S.I. and C.I. engine
Engine performance parameters (definitions only), BHP, IHP, FHP,
indicated thermal efficiency, mechanical efficiency, volumetric efficiency,
relative efficiency, mean effective pressure and specific fuel consumption.
(10 hrs)
2. Construction Details
Specifications, functions, working and materials of components – cylinder
block, cylinder head, cylinder liner, piston, piston rings and wrist pin,
connecting rod, crank-shaft, cam shaft, bearings, valves and valve
actuating mechanism, fly wheel and dampers.
Nomenclature of cylinder bore, piston area, stroke, dead centres (top and
bottom), swept volume, clearance volume, compression ratio
(8 hrs)
3. Fuel Supply System
Fuel supply circuits in petrol engine, function of various components in the
circuit, gravity, vacuum and pump feed systems, AC mechanical and electrical
fuel feed pump, fuel filters, fuel gauges – balanced coil and bi-metallic type.
(6 hrs)
77
4. Carburation
Theory of carburation, air fuel ratio required under various conditions of
operation of engine. Important circuits in carburetors – starting, idling, low
speed accelerating, economy and full power circuits. Automatic chokes,
description of solax and amal carburetors.
MPFI – Description and working of multipoint fuel injection. Advantages
and disadvantages of M.P.F.I
(8 hrs)
5. Ignition System
Phenomenon of carburation in petrol engine, type of spark ignition system,
battery/coil and magneto ignition system. Distributor: its function, layout and
drive. Automatic spark advance methods. C.B. point gap, spark plug gap
adjustment. Ignition timing. Electronic ignition system.
(4 hrs)
6. Cooling System
Necessity of cooling, types, direct and indirect, air cooling fins, blowers
application, indirect or coolant cooling, pump circulation system, water jacket,
water pump fan and its drive. Radiator and its types. Thermostat for
temperature control, temperature gauges, pressurized cap, anti-freeze
solutions, scale and corrosion.
(4 hrs)
7. Lubrication Systems
Various lubrication systems – splash, pressure and combined splash of
pressure lubrication, oil pumps, oil lines, filters, coolers, crank case
ventilation. Requirements of engine lubrication oils, their specifications, oil
consumption and additives for lubricants.
(4 hrs)
8. Air Supply/Intake and Exhaust system
Inlet and exhaust manifold, consideration for good manifold design, materials.
Various types of air cleaners – dry and wet, centrifugal. Exhaust silencers,
different types, valve timing diagrams
(4 hrs)
78
LIST OF PRACTICALS
1. Servicing of lubrication system – flushing crankcase, cleaning and replacing oil,
filter elements.
2. Servicing of fuel system – petrol feed system, cleaning, flushing fuel tank,
changing of fuel filters.
3. Servicing of feed pump, mechanical, electrical pump and testing.
4. Servicing of air cleaning.
5. Servicing of carburetor, cleaning and adjustment.
6. Setting of fuel injection pump timing of a diesel engine.
7. Overhauling of fuel injector and pump.
8. Servicing of valves and vale mechanism – replacement of valve, valve seats and
valve seats, checking and replacement of defective springs, facing of valves,
tappet and rocker arm, adjusting valve tappets.
9. Dismantling and assembling water pumps. Back – flushing of cooling
system/radiator.
10. Engine tune up
LIST OF BOOKS
1. Automobile Engineering by Dr. Kirpal Singh, Standard Publications.
2. Automobile Engineering by RB Gupta.
3. Automobile Engineering by Chitkara.
79
4.2 MATERIALS AND METALLURGY
L T P
3 - 2
RATIONALE
Materials play an important role in the construction and manufacturing of
equipment/tools. Right selection of materials add to the economy, working and life of
machinery. A diploma holder must be conversant with the properties, uses, availability
and costs of materials used for construction/fabrication to enable him to perform his
functions confidently. The subject of Materials and Metallurgy has been designed to
cover the above aspects.
DETAILED CONTENTS
1. Importance of Materials
Classification: Metals and non-metals, Ferrous and non-ferrous metals
and their alloys
Names of common metals, their alloys and non-metals used in
Industry
Properties of metals and alloys
Physical properties - Appearance, luster, colour, density and melting
point
Mechanical Properties: Strength, stiffness, elasticity, plasticity,
toughness, ductility, malleability, brittleness, hardness, fatigue and
creep.
Thermal and electrical conductivity
Corrosion, causes, effects and prevention.
(4 hrs)
2. Metallurgical Considerations
Solidification of metals form liquid to solid state of pure metals, cooling
curves of pure metals, dendritic solidification, crystal formation, types of
crystal structure. Phase diagram of:
(i) Solid-state solubility.
(ii) Partial solubility.
(iii) Nil solubility i.e. eutectic solution (Binary only). Effects of all
alloying elements on engineering materials. Effect of grain size
on mechanical properties.
(6 hrs)
80
3. Ferrous Metals and Alloys
Flow diagram for the production of ferrous metals from their ores,
constituents of iron, iron carbon diagram.
Classification, composition and uses of cast iron and plain carbon
steels. IS, BS and SAE Grades
Effect of alloying elements such as Aluminium, chromium, Nickel,
Cobalt, Manganese, Molybdenum, tungsten, Vanadium, Silicon,
Sulphur and Phosphorous on steels.
Composition, properties, grades and uses of special steels such as High
speed steel, Stainless steels, Silicon steels, Heat resistant steels, Spring
steel.
Heat Treatment: Iron-carbon diagram, objectives and practical aspects
of heat treatment. Brief description and uses with examples of
principal heat treatment processes, Annealing, Normalizing,
Tempering, Hardening, Carburising, Nitriding and Cyaniding and
applications. Examples in heat-treating engineering components time,
temperature transformation curve.
(12 hrs)
4. Non-ferrous Metals and Alloys
Copper: Properties and uses
Composition, properties and uses of copper alloys.
Brasses: Cartridge brass, Nickel silver.
Bronzes: Phosphor bronze, Al-bronze, Mn-bronze, and Gun metal.
Properties and uses of Aluminium.
Composition, properties and uses of Al-alloys e.g., Duralumin, Yellow
metal, Magnalium and Hindalium
Properties and uses of alloys of lead, tin and magnesium.
Bearing Metals: Requisite qualities. Composition, properties and uses
of white metal bearing, copper based bearing metals. Aluminium
based bearing metals. Use of nylon/PTFE for bushes/bearings, bimetallic
and tri-metallic bushes
(12 hrs)
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5. Identification and Examination of Metals and Alloys
Identification tests - Appearance, sound, filing, weight, magnetic, spark,
bend and microstructure. Different types of etchants for preparation of
surface structure.
(1 hrs)
6. Other Important Materials
Plastics: Definition, classification of plastics, fibre glass, reinforced
plastics. Major applications of various plastics and their uses and
grades.
Composite materials.
Heat insulating materials: Properties and uses of asbestos, glass wool,
thermocole, cork, mica.
Electrical insulating materials. Properties and uses of china clay,
leather, bakelite, ebonite, glass wool, rubber, felt.
Sound insulating materials: Cork, fibre boards.
Fabrication materials: Wood, plywood, rubber – natural and synthetic,
Glass – plate glass, toughened glass, safety glass.
Refractory materials: General characteristics and uses of dolomite,
ceramics.
Protective coating materials: Paints, primers, varnishes, enamels,
putti, electroplating materials, rubasil, teflon coating.
Sealant and adhesives – Application and availability of sealant and
adhesives for industrial user.
(10 hrs)
7. Selection, specifications and commercial availability of materials
Practical considerations for selection of material for different purposes
ISO/Bureau of Indian standard specifications for metals, non-metals,
various components and materials.
(3 hrs)
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LIST OF PRACTICALS
1. Classification of about 25 specimen of materials/parts in material lab, identify and
indicate the type of materials with respect to their properties
2. Study of metallurgical microscope.
3. To prepare microscopic structure for examination and to examine the micro
structure of specimens of various metals and alloys.
4. Study of heat treatment furnaces.
5. To study the effects of heat treatments processes on the following materials:
(i) Low carbon steel
(ii) Mild steel
(iii) High Carbon Steel
RECOMMENDED BOOKS
1. Material Science by GBS Narang, Khanna Publishers, New Delhi.
2. Material Science and Metallurgy by RB Choudary, Khanna Publishers, New
Delhi.
3. Material Science by RK Rajput; SK Kataria and Sons, Delhi.
4. Materials and Matallurgy by D.S. Nutt. SK Kataria and Sons, Delhi.
83
4.3 CHASSIS, BODY AND TRANSMISSION - I
L T P
3 - 3
RATIONALE
Chassis, body and transmission forms the core of automobile engineering. The subject
focuses at imparting knowledge and skills regarding chassis and body, viz. clutch system,
transmission system, drive system, steering mechanism, braking system, wheels and
tyres.
DETAILED CONTENTS
1. Chassis and Body
Classification of vehicles, layout of conventional type of chassis, function and
arrangement of major assemblies. Alternating arrangement used such as engine
position, drive types, their merits and demerits. Constructional details of car
body. Materials used for chassis frames, body components, interior body
dressing components, body upholstery, body streamlining, protective coatings
and body air-conditioning, types of frame and body, cross members, brackets,
materials for frame.
(6 hrs)
2. Clutch
Necessity, function and requirements of clutch, types of clutch - single plate,
multiplate clutch, wet and dry clutch, clutch plate and lining material
(5 hrs)
3. Transmission
Necessity, function, types and working of transmission – sliding, constant
mesh, synchromesh
(6 hrs)
4. Driveline
Propeller shaft - function, construction details. Universal joints - functions and
types. Constant velocity joints. Types of final drive – hotchkiss drive, torque
tube drive. Differential – principle, functions and its working, rear axles – semi
floating, fully floating, three quarter floating. Common faults and remedies
(8 hrs)
84
5. Steering
Types of front axles and their constructional details. Steering mechanism,
function Ackerman’s Principle of steering , working and constructional details
of steering gear, steering linkages, front and geometry-castor, camber, steering
axis inclination, toe in and toe out. Cornering force, cornering power and selfrighting
torque, over steering and under steering.
(8 hrs)
6. Braking System
Purpose of brakes, layout of hydraulic and mechanical braking system,
components. Principle of hydraulic brakes, braking action, master cylinder,
wheel cylinder, leading and trailing shoes, self adjusting and self releasing
action, its dissipation, antilock and antiskid devices, pedal travel, brake
enclosures, heat generation, its dissipation, and operating temperature, brake
drum and their material, lining materials, lining thickness and lining area, brake
shoes, shoe clearance, split brakes, hand brakes, brake fluids, disc brakes, brake
adjusters
(8 hrs)
7. Wheel and Tyres
Wheels – types, constructional details, specifications. Tyres - classification and
purpose. Types, construction of pneumatic tyres, details of carcass of various
types, comparison of cross-ply and radial-ply tyres, causes of excessive tyre
wear, effects of different conditions of vehicle stability. Tyre care and
maintenance, tubes and their types. Static and dynamic balance, retreading of
tyres, tubeless tyres.
(7 hrs)
LIST OF PRACTICALS
1. Identify and service single and multiplate clutch.
2. Servicing of steering system – steering gear boxes, correction and adjustment of free
play.
3. Servicing/overhauling of brakes – mechanical, hydraulic, brake adjustment and
bleeding.
4. Checking and adjustment of Camber, Caster, toe-in, toe-out, king pin inclination.
5. Removing dents and minor repair, body trimming and painting.
6. Wheel balancing – static and dynamic.
7. Practice in brake shoe riveting, de-riveting, aligning the shoes and adjustment of
brakes.
8. Servicing/overhauling of gear box.
85
RECOMMENDED BOOKS
1. Automobile Engineering, Vol. I by Dr. Kirpal Singh, Standard Publishers
2. Automotive Chassis and Body by PL Kohli
3. Automobile Engineering by GBS Narang, Khanna Publishers, Delhi
4. Automobile Engineering by CP Nakra
86
4.4 MANUFACTURING TECHNOLOGY - II
L T P
3 - 4
RATIONALE
Knowledge in various machining operations viz. drilling, boring, milling, planning and
grindin processes, finishing operations, gear production, CNC machining, bending
forming and welding processes is very essential for the diploma holders. Hence this
subject.
DETAILED CONTENTS
1. Drilling and Boring
Introduction, Types of drills, types of drilling machines i.e. portable, bench
type, piller and radial, drilling speeds and feeds, drill chucks and other
accessories (jigs etc.) used in drilling machines, reaming, introduction to
boring, types of boring machines – horizontal and vertical, specifications,
boring bar and boring heads
(8 hrs)
2. Machining Processes
Milling – Types of milling machines and their operations, speeds and
feeds, indexing (simple and compound), types of milling cutters
Planing machines and their operation
Grinding – cylindrical, centreless and surface grinding machines, types
of grinding wheels, specifications, grades and their selection, balancing
of grinding wheels and their storage
(12 hrs)
3. Finishing Operations
Lapping, honing, superfinishing operations and their applications, types of
abrasives used and their selection
(4 hrs)
4. Gear Production
Gear cutting and gear shaving machines, gear cutters and coolants
(4 hrs)
5. CNC Machines
Introduction to CNC control systems, advantages, productivity, accuracy
and cost
(4 hrs)
87
6. Bending and Forming
Description of press brakes, bending dies, forming machines
(4 hrs)
7. Welding
Introduction, types of welding (gauge welding, arc welding, resistance
welding), butt welding, flash, projection, seam and spot welding.
Selection of electrodes, filter metals, types of welding defects and their
remedies, soldering and brazing – processes and applications
Special welding processes for stainless steel and aluminium
(10 hrs)
8. Types of Coolants and Lubricants for various machining processes
(2 hrs)
LIST OF PRACTICALS
1. Introduction to drilling and boring machines, an exercise of simple drilling
and boring operation, selection of speeds and feeds, use of jigs and fixtures
and coolant.
2. Simple exercises on shaper
3. Practice on horizontal and vertical milling machines, work holding devices
and types of milling cutters
4. Practice on cylindrical and centreless grinding machine, selection, dressing
and storage of grinding machines. Use of lubricants
5. Practice on honing machines with selection of honing sticks, honing and
finish pattern in the bore. Bore geometry measurement
6. Observe working of CNC machines including setting of cutting parameters
and dimensions and loading of tools, repeatability of operation and
adjustment for wear allowances
7. Visit to industry (sheet metal shoos) to observe bending and forming
operation and use of dies
8. Use of appropriate coolant and lubricants for all machining operation in the
workshop and during Industrial visits.
RECOMMENDED BOOKS
1. Workshop Technology by BS Raghuwanshi, Dhanpat Rai & Sons, Delhi.
2. Workshop Technology Vol. – I, II & III by Chapman, Standard Publishers
Distributors, New Delhi.
3. Workshop Practice by RK Singhal, SK Kataria & Sons, New Delhi.
4. Production Technology by HMT, Tata McGraw Hill, New Delhi.
5. Elements of Workshop Technology by SK Chaudhary & Hazra, Asia Publishing
House.
88
4.5 AUTO ENGINEERING DRAWING - II
L T P
- - 6
RATIONALE
An automobile engineering diploma holder, irrespective of his field of operation in an
industry or transport undertaking, is expected to possess a thorough understanding of
engineering drawing, which includes clear spatial visualization of the subject and the
proficiency in reading and interpreting a wide variety of production drawings and
maintenance drawings. Besides this, he/she is also expected to have a certain degree of
drafting skills depending upon his job functions to perform his day-to-day activities e.g.
communicating and discussing the ideas with his superiors and passing on instructions to
his subordinates in an unambiguous way. Hence this subject. The teachers are
recommended to give more emphasis to the students by showing them automobile
components.
Note:
All assembly drawings to be made to scale except wherever mentioned otherwise
specifically
Candidates may be asked to show specific sections of the component/assembly
50% of the drawings shall also be made by AutoCAD for which no question shall be
set in the written paper
AutoCAD component shall be included in the practical/viva voce examination
DETAILED CONTENTS
1. Engine Components
AC fuel feed pumps (assembly)
Fuel injection pump (jerk type) (assembly)
Fuel injector (assembly
Overhead and side valve mechanism (free hand)
Water cooling system (free hand)
(24 hrs)
2. Chassis Components
Leaf spring suspension (assembly)
Shock absorber (assembly)
Internal expanding shoe brake (assembly)
Master cylinder (assembly)
Wheel cylinder (assembly)
Independent suspension system (free hand)
Brake drum (assembly)
Air assisted hydraulic brake system (free hand)
(33 hrs)
89
3. Auto Electrical Circuits (free hand sketches)
Electrical circuit of battery and magneto ignition system
Automobile gauges and meters circuit diagram
Automobile lighting and signaling circuits
Complete wiring diagram of a car
(12 hrs)
4. Transmission
Single plate clutch (assembly)
Gear box (free hand sketch)
Rear axle (fully floating) (free hand)
(18 hrs)
5. Garage
Free hand sketch of a bus
Free hand layout of a garage having a fleet of 100 vehicles
(9 hrs)
Note: 50% of drawings to be made using AutoCAD
RECOMMENDED BOOKS
1. Automobile Engineering Drawings by RB Gupta.
2. Machine drawings by PS Gill.
3. Machine Drawings by Laxmi Narayan and Mathur.
90
4.6 COMPUTER APPLICATIONS IN MECHANICAL ENGINEERING
L T P
- - 4
RATIONALE
Today age is computer age. Most of our daily activities are being influenced by the use
of computers. While in areas like science and technology, improvements cannot be
achieved without computers. It has become necessary for each and everyone of us to
have a basic knowledge of application of computers. PowerPoint is a feature packed
presentation programme whereas access is database management systems. Programming
is backbone for preparing various technological projects, which can be achieved by C++
language – most versatile one in today’s scenario. This subject is being offered to
acquaint the students about MS PowerPoint, MS Access and Programming using C++
language.
DETAILED CONTENT
1. Computer Application Overview
(3 hrs)
Commercial and business data processing applications
Engineering computation
2. MS PowerPoint
(15 hrs)
2.1 Introduction
Elements of power point package- templates, wizards, views, color schemes
Starting PowerPoint
Exploring PowerPoint menus
Starting a new slide
Adding title, text and art
Moving text area and resizing text box
Starting a slide show
Saving a presentation
Printing slides
Inserting and deleting slides
Closing a presentation
Exercise for making a presentation and slide show
2.2 Views
PowerPoint views – slide view, outline view, slide sorter view, notes view, slide
show view, slide setup
Zoom in, zoom out
Exercises on various views of presentation
91
2.3 Formatting and Enhancing text
Formatting
Changing format with a new layout
Alignment of text and text spacing
Enhancing text formatting – use of bullets, changing text font and size
Selecting text style and color
Applying design template
Closing and applying the transition
Spell checking
To set header and footer
Exercise on formatting text and applying design template.
2.4 Slide with graphs
Creating a graph
Adding graphic objects
Adding clipart pictures
Adding movies and sounds
Adding multimedia to presentation
Inserting excel worksheet or word table
Exercise on inserting graphs, tables, movies and clipart.
3 MS - Access
(16 hrs)
3.1 Introduction to Microsoft access
Components of access
3.2 Table creating
Starting access, creating tables, tool bars and views of tables
Editing the design and contents of the table
Creating relationship between tables
Adding OLE objects to a table
Use of import and export facility
Exercise on table creating
3.3 Query Handling
Creating a new query, use of criteria, expressions and operation
Editing a query, print a query
Exercise on creating and editing query
3.4 Form designing
Introduction, creating a form, modify a form design, designing a form using
design view.
Sub – forms, printing the forms, exercise on form designing.
92
3.5 Report designing
Creating a report, managing the different controls of the records, saving and
printing the report, use of graphs in reports
Exercise on report designing
4 Programming fundamentals
(6 hrs)
Algorithm, pseudo language, flow charts: advantages and disadvantages
Decision table – type, advantages and disadvantages
Structured programming: structuring the control flow, modular programming
Exercise on making algorithm and flow charts.
5 C++ programming
(24 hrs)
5.1 Fundamentals
Introduction, oop, character set, C++ tokens, keywords, identifiers, constants,
basic data type, declaration of variables, defining symbolic constants, assignment
statement, comments in a programme, structure of C++ programme, output using
COUT, output using CIN, manipulators.
5.2 Operators and Expressions
Arithmetic operators, relational operators, logical operators, shorthand assignment
operator, increment and decrement operators, conditional operators, bit wise
operators, precedence in C++ operators, casting of data, standard mathematical
functions.
5.3 Control structures
IF statements, IF---ELSE statements, nested IF statements, switch statements, Go
To statements, repetitive structures, while statements, do statement, for loop,
break statement, continue statement, nested loops.
5.4 Programs
Write a program to check if a number is even or odd.
Write a program to find the smallest of 3 numbers.
Write a program to find largest of 4 numbers
Write a program to find the roots of quadratic equation.
Write a program to find the sum of the first N natural numbers using a for - do
loops.
Write a program that reads in N numbers and finds the smallest number among
them.
Write a program to find the sum of squares of the digits of a number.
6. Demonstration of CNC machine
RECOMMENDED BOOKS
1. MS Office 2000 for everyone by Sanjay Saxena; Vikas Publishing House Pvt. Ltd.
2. MS Office 2000 by Steve Hill; BPB Publications.
3. Programming in C++ by B. Subharamanayam.
4. Programming in C by Abdul Khader; Ajanata Publications
93
INDUSTRIAL TRAINING
Industrial Training aims at exposing the students to field practices, size and scale of
operations and work culture at practical sites. For this purpose, students at the end of
fourth semester, are required to be sent for a period of 4 weeks at different work sites.
Each student is supposed to study the material and technology used at site and prepares a
detailed project report of the observation of processes seen by him/her. These students
should be supervised and guided by respective subject teachers. Each teacher may guide a
group of four to five students.
The teacher along with field supervisors will conduct performance assessment of
students. The components of evaluation will include the following.
- Punctuality and regularity 15%
- Initiative in learning new things 15%
- Relationship with workers 15%
- Industrial training report 55%
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