Introduction to Mechanical Engineering [22ESC144]

Module-1

Chapter 1

Introduction to Mechanical Engineering:

Role of Mechanical Engineering in Industries and Society- Emerging Trends and
Technologies in different sectors such as Energy, Manufacturing, Automotive, Aerospace,
and Marine sectors.

Introduction to Mechanical Engineering

Mechanical Engineering is one of the oldest engineering professions. Mechanical

Engineering can trace its roots back to the very beginning of the Industrial Revolution, from
1750 to 1800 in Europe and 1800 to 1850 in the United States. The invention of the steam
engine by James Watt in 1802, propelled the growth in this field by leaps and bounds. After
the invention of the automobile, both the need for precisely machined metal and a more
formalized method of assembling the components.

Mechanical engineering is the study, design, development, construction, and testing of

mechanical and thermal sensors and devices, including tools, engines, and machines.
Mechanical engineering careers centre on creating technologies to meet a wide range of
human needs.

Mechanical engineering subjects include automobile engineering, manufacturing engineering,

power plant engineering, thermal engineering, and mechatronics engineering, which is a
combination of electrical, computer, and mechanical engineering.

Role of Mechanical Engineering in Industries and Society:

Mechanical Engineer will play a vital role in the sustainable development of the industry and
the society. Starting from the conceptualization of the product to the design, manufacturing,
sales and service to the end of life of a product i.e, recycling mechanical engineer will play
his role.
To start with, for a design a product mechanical engineer has to conceptualize the product,
draw the preform of the product, then apply the mechanical design and will build the product
for its strength.

Mechanical engineer role as a manufacturing Engineering is a huge. Studying the design,

laying out the tooling for the production and optimize the raw material consumption in the
manufacturing a component requires huge skills as a mechanical Engineering.

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Mechanical Engineer also places a vital role in the logistics. Procuring the materials for the
production, maintaining the adequate material in the stores, dispatching the finished products
to the Consumer is the role of a Logistic Engineer.

Mechanical Engineer also works as a safety Engineer in an Industry. Taking care of the
human resources, machineries, equipment’s and planning out the safer working conditions
and ensuring the safety of the operations is the responsibility of the safety engineer.

Mechanical Engineer plays a vital role in the overall growth of the economy as well as the
Society. Meeting the demand for a product to the optimum utilization of the resources taken
care by the mechanical Engineer. Designing a product for longer product life cycle and
reutilization/ recycling the product reduces the dependency of the materials by the industry.
Also, developing newer equipment’s, devices for harnessing the renewable sources energy
reduces the dependencies on the fossil fuels. This in turn contribute the green energy, low or
no emission of carbon and its compounds.

Following are few of the areas where in Mechanical Engineer play his role in an industry:
Design Engineer Production Manager, Safety Engineer, QA Engineer, Logistic Manager,
Data analyst, Drafts man, Sales Executive, Customer Service etc.,

Emerging Trends and Technologies in Mechanical Engineering in different Sectors:

Energy: The energy sector is a category that relate to producing or supplying energy. The
energy sector or industry includes companies involved in the exploration and development of
oil or gas reserves, oil and gas drilling, and refining. The energy industry also includes
integrated power utility companies such as renewable energy and coal.

Figure: Solar PV Panels and Wind Turbines

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Advent of technology and raising concern on the use of fossil fuels gives an opportunity to
think of the energy harnessing through renewable resources. Increased efficiency in the solar
PV cells, ease in the manufacturing of complicated shapes of a wind turbine blades through
various manufacturing process, newer innovations in the electric vehicles, newer materials
compositions to produce parts used in devises etc., creating the opportunity to extract the
energy at low cost through renewable sources and avoiding the dependency on fossil fuels.

Manufacturing: Manufacturing is the process of converting the raw material into a finished
product. The technology had taken a great leap in the manufacturing sector. Along with side
of conventional manufacturing methods other manufacturing methods are also practicing in
the industry. Lean manufacturing, just in time manufacturing (JIT), Flexible manufacturing
system (FMS), Computer Integrated manufacturing (CIM) are already in use. Along with this
additive manufacturing is getting its importance in the new product development which
reduces the material and time.

Figure: CNC machine tool in Turning Operation

Automotive Industry:

Figure: Concept of electric vehicle during docking

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Indian Automobile market is the 3rd Largest automobile market in the world. The automobile
market seen a considerable changes in the advance of technology. Electric vehicles are the
next alternative to the conventional fossil fueled vehicles. Providing the better customer ride
experience electric vehicles are the future of automobile market. Also, Hybrid vehicles are
already in market uses dual fuel technology like electric and gasoline. Automation is another
aspect in the automobile industry. Use of mechatronics, internet, AI automobile
manufacturers are striving for the better user interface and comfort in automobile experience.

Aerospace Industry: Invention of new materials like composites, shape memory alloys
added the strength to weight ratio among the material used in the production of Aerospace
vehicles. Also, use of sophisticated manufacturing techniques in the building of aircrafts
make the cost of the air craft vehicles much economical.

Marine Sector: Marine engineering is the discipline that deals with matters related to the
design, innovation, construction and maintenance of seagoing vessels and navigation
equipment. Marine engineers focus primary on the development and production of internal
systems of boats, ships, or submarines. They are engaged in designing propulsion systems,
auxiliary power machinery and operation equipment. Their technical responsibilities also
include working on-board to maintain these systems.

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Chapter 2
Energy: Introduction and applications of Energy sources like Fossil fuels, Nuclear fuels,
Hydel, Solar, wind, and bio-fuels, Environmental issues like Global warming and Ozone
depletion.
Review of energy sources:
• “Energy‟ is a word derived from the Greek word Energia‟, meaning capacity to do
work. Energy exists in various forms.
• The form of energy that bodies in motion possess is called kinetic energy.
• The energy related to the position of a body is called potential energy.
• The energy contained in a chemical system by virtue of the motion of and forces
between the individual atoms and molecules of the system is called internal energy.
There are different other forms of energy namely, kinetic energy, potential energy,
internal energy, mechanical energy, thermal energy, chemical energy etc. All forms of
energy are inter-convertible by appropriate processes.

ENERGY SOURCES:

Energy exists in the earth or comes from the outer space. The energy existing in the
earth is called capital energy and that which comes from the outer space is called celestial or
income energy. E.g. of capital energy: fossil fuels, nuclear fuels and heat traps. E.g. of
celestial or income energy: Electromagnetic energy, gravitational energy, particle energy and
potential energy of meteorites. The useful celestial energy sources are the electromagnetic
energy of the Sun, called direct solar energy. The gravitational energy of the Moon produces
tidal energy. The other sources such as wind energy, hydel energy, geothermal energy,
biofuels etc. are derived from the direct solar energy.
Renewable and non-renewable sources of energy
The conventional and non-conventional energy sources have been classified as renewable
and non-renewable energy sources, depending on whether these sources are continuously
available or will be exhausted.
The renewable sources of energy are defined as the energy sources which are
continuously produced in nature and are essentially inexhaustible at least in the time frame of
human societies. 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. Of the

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above renewable energy sources, geothermal energy, peat and fuel wood must be used at a
rate less than their renewal rate in the nature, to allow them to build up again in nature.
The non-renewable energy sources are defined as the energy sources which have
been accumulated over the ages and not quickly replenishable when they are exhausted. E.g.
Fossil fuels (coal, petroleum and petroleum products), nuclear fuels and heat traps.

Advantages of renewable energy sources

1. The renewable energy sources are non-exhaustible.

2. Renewable energy sources can be matched in scale to the need and also can deliver
the energy required for a specific task.

3. Some of the renewable energy conversion systems can be built on or close to the site
where energy is required.

4. The diversity and technologies of renewable energy conversion systems offer more
flexibility in designing the conversion systems compared to the conventional energy
conversion systems.

5. The local or regional self-sufficiency can be achieved by harnessing locally available

renewable energy, which otherwise would be left unutilized.

6. Except biomass energy, all other renewable energy sources offer pollution-free
environment and maintain ecological balance.

Disadvantages of renewable energy sources

1. Some of the energy sources are intermittently available (i.e. not continuously
available). E.g. solar energy, tidal energy, wind energy etc.
2. There is a limit to the rate at which solar energy is received at the Earth.
3. Renewable energy sources like wind energy, tidal energy etc. are concentrated only in
certain regions.
4. State-of-the-art technology in harnessing the renewable sources is yet to be developed
to meet the present day energy requirements.
5. Application of renewable energy sources in transportation sector is not viable as of
today.

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Differences between renewable and non-renewable sources of energy

Sl. No. Renewable energy sources Non-renewable energy sources

1 Inexhaustible in nature. Exhaustible in nature.
2 Most of the renewable energy sources are Most of the non-renewable energy sources
freely and readily available in nature. are not readily available in nature.
3 Non-reliable since energy concentration Reliable, since energy concentration is
varies from region to region and time to almost constant in all regions.
time.
4 Initial costs of extracting energy are high. Initial costs are comparatively less.
5 Rarely used due to limitations in their Widely used due to maximum availability
equipment’s. of their equipment’s.
6 Energy transmission cost is less. Energy transmission cost is relatively more.
7 Eco-friendly in nature. Not eco-friendly in nature.
8 Maintenance cost is low. Maintenance cost is high.
9 Energy conversion equipment’s are not well Energy conversion equipment’s are well
developed. developed.
10 Energy conversion equipments are of low Energy conversion equipments are of
efficiency. relatively high efficiency.
11 E.g. direct solar energy, wind energy, tidal E.g. Fossil fuels (coal, petroleum and
energy, hydel energy, ocean thermal petroleum products), nuclear fuels and heat
energy, bio energy, geothermal energy, traps.
peat, fuel wood, fuel cells, solid wastes,
hydrogen energy etc.

Fossil Fuels:
• Fossil fuels are non-renewable energy resources; these are coal, oil and natural gas.
• They were formed from the remains of living organisms millions of years ago and
they release heat energy when they are burned.
• This heat is used to turn water into steam, which is used to turn a turbine, which then
drives a generator to generate electricity.
• There are downsides however, fossil fuels release Sulphur dioxide and carbon dioxide
which lead to acid rain and an increase in global warming.

Construction & Working of Thermal Power Plant:

It is the power plant which is used to generate electricity by the use of steam turbine. The
major components of these power plants are boiler, steam turbine, condenser, and water feed
pump.

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Figure: Layout of Thermal Power Plant

Working of Thermal Power Plant:
• In the steam power plant, the pulverized coal is fed into the boiler and it is burnt in the
furnace. The water present in the boiler drum changes to high pressure steam.
• From the boiler the high-pressure steam passed to the superheater where it is again
heated up to its dryness.
• This superheated steam strikes the turbine blades with high speed and the turbine
starts rotating at high speed.
• A generator is attached to the rotor of the turbine and as the turbine rotates it also
rotates with the speed of the turbine. The generator converts the mechanical energy of
the turbine into electrical energy.
• After striking on the turbine the steam leaves the turbine and enters into the
condenser. The steam gets condensed with the help of cold water from the cooling
tower. The condensed water with the feed water enters into the economizer.
• In the economizer the feed water gets heated up before entering into the boiler. This
heating of water increases the efficiency of the boiler.
• The exhaust gases from the furnace pass through the superheater, economizer and air
pre-heater. The heat of this exhaust gases is utilized in the heating of steam in the
superheater, feed water in the economizer and air in the air pre-heater.
• After burning of the coal into the furnace, it is transported to ash handling plant and
finally to the ash storage.

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Advantages:
▪ Less initial cost as compared to other generating stations.
▪ It requires less land as compared to hydro power plant.
▪ The fuel (i.e., coal) is cheaper.
▪ The cost of generation is lesser than that of diesel power plants.
Disadvantages:
▪ It pollutes the atmosphere due to the production of large amount of smoke. This
is one of the causes of global warming.
▪ The overall efficiency of a thermal power station is low (less than 30%).

Construction and working of Hydel power plant

A power plant that utilizes the potential energy of water for the generation of electrical
energy is known as a hydroelectric power plant.

Hydroelectric power plants are generally located in hilly areas where dams can be built
easily, and large water reservoirs can be made. In a hydropower plant, a water head is created
by building a dam across a river or lake. From the dam, water is fed to a water turbine.

Working Principle of Hydroelectric Power Plant

The water turbine changes the kinetic energy of the falling water into mechanical energy at
the turbine shaft. In simple words, falling water spins the water turbine. The turbine drives
the alternator coupled with it and converts mechanical energy into electrical energy. This is
the basic “working principle of hydroelectric power plant.”

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Water from the dam through sluice gate enters the penstock where its pressure increases and
at the entry of Power house the pressure energy converts to kinetic energy. This water having
kinetic energy passes through turbine and rotational energy is produced. The turbine is
coupled to generator where rotational energy is converted to Electrical energy. The water is
sent out with normal atmospheric pressure.

Construction & Working of Nuclear Power Plant:

The schematic diagram of nuclear power station is shown in figure. A generating station in
which nuclear energy is converted into electrical energy is known as nuclear power station.
The main components of this station are nuclear reactor, heat exchanger or steam generator,
steam or gas turbine, AC generator and condenser.

Figure: Schematic Arrangement of Nuclear Power Plant

The reactor of a nuclear power plant is similar to steam power plant. The heat liberated in the
reactor due to the nuclear fission of the fuel is taken up by the coolant circulating in the
reactor. A hot coolant leaves the reactor at top and then flows through the tubes of heat
exchanger and transfers its heat to the feed water on its way. The steam produced in the heat
exchanger is passed through the turbine and after the work has done by the expansion of
steam in the turbine, steam leaves the turbine and flows to the condenser. The mechanical or
rotating energy developed by the turbine is transferred to the generator which in turn

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generates the electrical energy. Pumps are provided to maintain the flow of coolant,
condensate, and feed water.

Solar Energy:
Solar energy is the energy obtained by capturing heat and light from the Sun. Energy from
the Sun is referred to as solar energy. Technology has provided a number of ways to utilize
this abundant resource. It is considered a green technology because it does not emit
greenhouse gases. Solar energy is abundantly available and has been utilized since long both
as electricity and as a source of heat.
There are several ways the solar energy can be harnessed. Such as;
a) Solar Photovoltaic Conversion (Helio- Electrical Process)
b) Solar Thermal Conversion (Helio-Thermal Process)
For, electricity generation Solar P-V cells are used at a larger extent.
Solar Power Plant (PV Cells):
The major components of the Solar power are plants are: Solar Panels, Solar cells, Battery
and Invertor.

Figure: Working Principle of Solar Power Generation / PV Cell

As sunlight falls over a solar cell, a large number of photons strike the p-type region of
silicon. Electron and hole pair will get separated after absorbing the energy of photon. The
electron travels from p-type region to n-type region due to the action of electric field at p-n
junction. Further the diode is reversed biased to increase this electric field. So, these current
starts flowing in the circuit for individual solar cell and combining the current of all the solar
cells of a solar panel, to get a significant output.

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Solar power plant has a large number of solar panels connected to each other to get a large
voltage output. The electrical energy coming from the combined effort of solar panels is
stored in the Lithium-ion batteries to be supplied at night time, when there is no sunlight.

Solar Thermal Conversion (Helio-Thermal Process): Flat Plate Collector

The heating property of solar radiation is used in the devices to meet the thermal energy
needs. It is necessary to collect and concentrate the solar radiation in an efficient manner to
arrive a reasonably high-temperature heat source. The collectors gather the sun’s energy and
direct it onto receivers that contain the working fluid.
The flat plate collector is a device used to absorb and store solar energy. The stored energy is
used for domestic, agriculture or industrial applications. The construction of flat plate
collector is very simple.
The flat plate collector consists of a metal sheet (absorber surface) exposed to the solar
radiation. This sheet absorbs both beam and diffused solar radiation. The sheet is coated with
black paint. Fluid carrying pipes are connected to back side of the metal sheet. The liquid
most commonly used is water. The lower side of metal sheet is covered with insulating
material. The transparent cover (glass) is fixed above the metal sheet, which reduces the heat
loss due to convection & radiation. The flat plate collector efficiency is good at medium and
maximum temperatures, but at low temperature the efficiency is very low. The flat plate
collectors are designed for output temperatures ranging from 60º C to 100º C.

Figure : Solar Flat Plate Collector

Cold water from overhead tank enters the flat plate collector from bottom and flows over the
copper tubing which is having more temperature because of solar radiation. Because of the
natural phenomenon of heat flow from hot to cold regions, because of this water observes the

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temperature in the tube and becomes hot water. This hot water will reach the tank from top of
the system as shown in the figure.
Wind Power:
Wind energy is defined as the kinetic energy associated with the moment of large mass of air
over the earth surface. The circulation of air is caused by the uneven heating and cooling of
the earth surface. In general, during the daytime the land masses heated up faster than sea
hence air moving over the land masses heated up and becomes less dense. This makes the
cold denser air from the sea blow towards the land masses.
But during the night, the land cools faster than the sea and hence, the denser air from the
landmasses starts moving towards the sea. That is offshore.

Figure: Schematic Arrangement of a wind turbine parts

Above figure shows the schematic arrangement of windmill. The major parts of a windmill
are hub, blades, nasal, tail, yawing mechanism and tower.
Working principle:
As the wind flows over the windmill, the blades of the mill start rotating slowly. Blade starts
rotated because of their aerodynamic profile. The wings are connected to hub, which is in
turn connected to main driving shaft, which is intern connected to gearbox. The function of
the gearbox is to increase the speed of the shaft which is connected to the generator. The
generator generates the power and transmits to grid. The minimum velocity in air required to
run the windmill is more than five meter per second.

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Biofuels
Biofuel, any fuel that is derived from biomass—that is, plant or algae material or
animal waste. Since such feedstock material can be replenished readily, biofuel is considered
to be a source of renewable energy, unlike fossil fuels such as petroleum, coal, and natural
gas.“Biofuel is an inexhaustible, biodegradable fuel manufactured from Biomass.”
• Biofuel is considered pure and the easiest available fuels on planet earth. Biofuels are
obtained from biomass like wood and straw, which are released by direct combustion
of dry matter and convert into a gaseous and liquid fuel.
• Other sources include organic matter like sludge, sewage and vegetable oils matter,
which can be converted into biofuels by a wet process like digestion and fermentation.
Types Of Biofuels
Biofuel is generally available in all regions of the world, which mainly include fuels like:
1. Biodiesel
2. Bioethanol
3. Bio methanol
The two most common types of biofuels in use today are bioethanol and biodiesel. Both of
which represent the first generation of biofuel technology.
Wood, straw and domestic refuse are used as a source of heat and energy. Biofuels can also
be produced from animal fats, plant wastes and other organic wastes produced from living
organisms.
This process is divided into three categories:
1. First-generation: Biofuels are primarily produced from edible sugar, starch and other
food crops are grown on arable land.
2. Second generation: Biofuels are produced from non-edible plant materials, such as
plant dry matter or woody biomass, or agricultural residues and wastes.
3. Third generation: Biofuels are primarily produced from algae and microbes. Algal
fuels have high yields.
Process Of Biofuels

1. The crops of selected plants are let out freely to absorb the heat from the sun.
2. Later these crops are refined in factories to produce food products
3. Once the food products are produced, these crops are refined to produce biofuel.
4. After the production of biofuels, they are collected in tanks and used for a different
process.

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GLOBAL WARMING
A gradual increase in the overall temperature of the earth's atmosphere generally attributed to
the greenhouse effect caused by increased levels of CARBON DIOXIDE, CFCS, and other
pollutants.
➢ Troposphere, the lowermost layer of the atmosphere, traps heat by a natural process due to
the presence of certain gases. This effect is called Green House Effect as it is similar to the
warming effect observed in the horticultural greenhouse made of glass.
➢ The amount of heat trapped in the atmosphere depends mostly on the concentrations of heat
trapping. or. green house. gases and the length of time they stay in the atmosphere.
➢ The major greenhouse gases are carbon dioxide, ozone, methane, nitrous oxide,
chlorofluorocarbons (CFCs) and water vapors.
➢ The average global temperature is 15°C. In the absence of greenhouse gases this temperature
would have been -18°C. Therefore, Green House Effect contributes a temperature rise to the
tune of 33°C.
➢ Heat trapped by greenhouse gases in the atmosphere keeps the planet warm enough to allow us
and other species to exist.
➢ The two predominant greenhouse gases are water vapors, which are controlled by hydrological
cycle, and carbon dioxide, which is controlled mostly by the global carbon cycle.
➢ While the levels of water vapor in the troposphere have relatively remained constant, the levels
of carbon dioxide have increased.
➢ Warming or cooling by more than 2°C over the past few decades may prove to be disastrous
for various ecosystems on the earth including humans, as it would alter the conditions faster
than some species could adapt or migrate.
➢ Some areas will become inhabitable because of drought or floods following a rise in average
sea level.
OZONE LAYER DEPLETION
➢ Ozone is a form of oxygen. The molecule of oxygen contains two atoms whereas that of
ozone contains three (O3).
➢ In the stratosphere ozone is continuously being created by the absorption of short wavelength
ultraviolet (UV) radiations.
➢ Ultraviolet radiations less than 242 nanometers decompose molecular oxygen into atomic
oxygen (O) by photolytic decomposition.
O2 + (UV) → O + O
➢ The atomic oxygen rapidly reacts with molecular oxygen to form ozone.
O + O2 + M → O3 + M

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➢ Chlorofluorocarbons (CFC) are mainly responsible for ozone depletion in the stratosphere
➢ Nitrous oxide emitted by supersonic aircrafts, during combustion of fossil fuel and use of
nitrogen fertilizers breaks ozone molecules.
➢ Ozone depletion in the stratosphere will result in more UV radiation reaching the earth
especially UV-B (290-320 nm). The UV-B radiations affect DNA and the photosynthetic
chemicals. Any change in DNA can result in mutation and cancer. Cases of skin cancer
(basal and squamous cell carcinoma) which do not cause death, but cause disfigurement.
➢ Easy absorption of UV rays by the lens and cornea of eye will result in increase in incidents
of cataract.
➢ Melanin producing cells of the epidermis (important for human immune system) will be
destroyed by UV-rays resulting in Immuno-suppression. Fair people (can’t produce enough
melanin) will be at a greater risk of UV exposure.
➢ Phytoplankton (microalgae) are sensitive to UV exposure. Ozone depletion will result in
decrease in their population thereby affecting the population of zooplankton, fish, marine
animals, in fact the whole aquatic food chain.
➢ Yield of vital crops like corn, rice, soybean, cotton, bean, pea, sorghum and wheat will
decrease.
➢ Degradation of paints, plastics and other polymer material will result in economic loss due to
effects of UV radiation resulting from ozone depletion.

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