BASICS OF

MECHANICAL
ENGINEERING
SUGOOR NAGAPPA
Assistant Professor
Department of Mechanical Engineering
Vignan’s Institute of Information Technology (A)
Syllabus
Syllabus
Syllabus
 OBJECTIVES
Introduction

What is Mechanical Engineering

Role of Mechanical Engineering in Industries and Society

Technological development in different Sectors

Introduction to Engineering Materials

Classification of Engineering Materials

Ferrous materials

Non ferrous materials

Ceramics materials

Composite and Smart materials

 What is
Engineering?
❖ Engineering is the application of science and maths to
design or make things and to solve the technical
problems.
❖ Engineers figure out how things work and find practical
uses for scientific discoveries.
 What is Mechanical Engineering?
❖ Creation and development of mechanical systems for all of humankind
concern with principles of force, energy and motion
❖ Involves design, manufacturing, inspection and maintenance of machinery,
control systems
❖ Ex. Vehicles, construction, farm machinery, industrial installations and a
wide variety of tools and devices.
 Role of Mechanical Engineering in Industries and Society
❖ Mechanical Engineering plays a crucial role in driving innovation and achievements in various
industries
❖ Mechanical engineers design power-producing machines, such as electric generators, internal
combustion engines, and steam and gas turbines, as well as power-using machines, such as
refrigeration and air-conditioning systems.
❖ Mechanical engineers design other machines inside buildings, such as elevators and escalators.
❖ Design and manufacturing of plant equipment like refineries, heat exchangers, pipe lines etc
❖ Mechanical Engineering contributes to the growth of industries such as:
• Automotive
• Aerospace
• Transportation
• Defense
• Medical Industry
• Agricultural
 Technological Developments in Different Sectors
• Contribution to public
transport systems by
designing and developing
various components, such
as propulsion systems,
braking systems, HVAC
systems, and structural
components.
• They can also design and
test safety systems,
including emergency
brakes and collision
 Technological Developments in Different Sectors
• Design And Development Of
Weapons Systems
• Vehicle Design And
Development
• Prototyping And Testing
• Manufacturing And
Maintenance
• Quality Control And
Assurance
 Technological Developments in Different Sectors

Designing and Developing

Agricultural Machinery:
• Mechanical engineers can be
involved in the design and
development of various
agricultural machinery and
equipment
• Tractors, harvesters, tillers, and
irrigation systems.
 Technological Developments in Different Sectors
❖ Engineer's responsibilities in
medicine can include research,
development, testing and
evaluation of medical devices
❖ Advisement on new biomedical
purchases for hospitals and
medical centers
❖ Development of new surgery
equipment
 Technological Developments in Different Sectors
❖ Engineers can contribute to
design and make heavy
machinery like boilers and
turbines.
❖ Advanced power systems, using
mathematical models, software
tools, and engineering principles
to solve power generation,
transmission, distribution
❖ Solar energy generation
❖ Wind mills to produce power
 What is Engineering Material
❖ Engineering materials refers to the group of materials that are used in the construction of
manmade structures and components.
❖ The primary function of an engineering material is to withstand applied loading without
breaking and without exhibiting excessive deflection.
❖ The major classifications of engineering materials include metals, polymers, ceramics, and
composites.
 Properties of Engineering Material
Mechanical Properties:
❖ Strength: The ability of a material to withstand an applied
force without failure. This includes tensile strength,
compressive strength, and shear strength.
❖ Stiffness: The material's resistance to deformation when
subjected to an external load.
❖ Hardness: The resistance of a material to abrasion,
indentation, or scratching.
❖ Toughness: The ability of a material to absorb energy
before fracturing.
❖ Elasticity: The capacity of a material to return to its original
shape after deformation.
❖ Ductility: The ability to be stretched or bent without
breaking.
❖ Brittleness: The tendency of a material to fracture without
significant deformation.
❖ Fatigue Resistance: The ability to withstand repeated
loading and unloading without failure.
Classification of Engineering
Materials
 Metallic Materials
❖ Metals is naturally occurring element which posses lustrous nature
❖ Metallic materials composed of one or more metallic elements and containing metallic bond
❖ Good conductors of heat and electricity
❖ Aluminium, Iron, Gold, Copper, Silver etc.
❖ Non-metals are natural materials that do not produce heat or electricity
❖ Hydrogen, carbon, nitrogen, oxygen, phosphorus, arsenic and selenium are the non-metallic
elements in the periodic table.
 Ferrous Materials
❖ Ferrous materials, those of which iron is the prime constituent.
❖ Based on the carbon content and other alloying elements ferrous materials
are divided into two categories i.e. Steel and Cast
❖ They are especially important as engineering construction materials.
❖ Their widespread use is accounted for by three factors:
✔ Iron-containing compounds exist in abundant quantities within the
earth’s crust
✔ Metallic iron and steel alloys may be produced using relatively
economical extraction, refining, alloying, and fabrication techniques
✔ Ferrous alloys are extremely versatile, in that they may be tailored to
have a wide range of mechanical and physical properties
❖ The principal disadvantage of many ferrous alloys is their susceptibility to
 Steels

❖ Steels are iron–carbon alloys that may contain appreciable

concentrations of other alloying elements
❖ The mechanical properties are sensitive to the content of
carbon, which is normally less than 1.0 wt%.
❖ Some of the more common steels are classified according to carbon
concentration namely, into low, medium, and high carbon.
❖ Subclasses also exist within each group according to the
concentration of other alloying elements.
❖ Plain carbon steels contain only residual concentrations of
impurities other than carbon and a little manganese.
❖ For alloy steels, more alloying elements are intentionally added in
specific concentrations
 Properties and Applications of Steels
Properties
The properties of steel depend
on its constituents:
• High Ductility
• Good Tensile strength
• Good Compressive strength
• High Yield strength
• High Ultimate strength
• Resistance to Fatigue
• Good Malleability,
• High Creep strength,
• Elongation,
• Low-weight,
• Hardness
Applications
Steel applications can be divided into seven primary market
sectors:
• Buildings and infrastructure - 51%: reinforcing bars,
sheet products, roofs, internal walls, and ceilings and
structural sections, tunnels, rail track, fueling stations,
train stations, ports, and airports.
• Mechanical equipment - 15%: Hand tools such as
hammers and shovels, rolling mills
• Automotive - 12%: body structure and exterior, including
the doors. Bulldozers, tractors, car parts, cranes, and
suspension.
• Metal products - 11%: furniture, packaging for food and
drinks, and razors.
• Other transport - 5%:
• Domestic appliances - 3%: Clothes washers and dryers,
ranges, microwave ovens, dishwashers, and refrigerators
• Electrical equipment - 3%: transformers, generators,
 Classifications of Steels
❖ Depending on its constituents, steel can be classified into the
following types:

1. Carbon Steels
2. Tool Steels
3. Stainless Steels
4. Alloy Steels
Classifications of Steels
 Cast Iron
❖ Cast iron is an alloy of iron with 2% - 4% carbon with different compositions of silicon
and manganese.
❖ It also has the composition of impurities of sulfur and phosphorus.
Applications
Characteristics:
✔ Excellent bearing properties ✔ Engine blocks and cylinder heads,
manifolds, gas burners, gear blanks,
✔ Excellent damping properties enclosures, and housings
✔ Excellent wear resistance (hi C)
✔ Mill linings, shot-blasting nozzles, railroad
✔ Hard, and brittle
brake shoes, slurry pump housings, rolling
✔ High compressive stress mill rolls, and crushers
✔ Excellent machinability
✔ Steering knuckles, plow shares, crankshafts,
✔ High ductility heavy duty gears, automotive and truck
✔ Good fatigue strength and suspension components, hydraulic
wear resistance, components, and automobile door hinges
✔ Shock resistance and high ✔ Heavy duty bearing surfaces, chains,
modulus of elasticity. sprockets, connecting rods, drive train and
axle components, railroad rolling stock, and
farm and construction machinery
Applications of Cast irons
 Non - Ferrous
Materials
❖ The non ferrous materials have some element other than iron as the principle constituent.
❖ The bulk of the nonferrous materials is made up of the alloys of copper, aluminum,
magnesium, nickel, tin, lead, titanium and zinc.
❖ Other nonferrous metals and alloys that are used to a lesser extent include cadmium,
molybdenum, cobalt, zirconium, beryllium, tantalum, and the precious metals gold, silver and
the platinum group.
❖ Properties:
✔ High Ductility
✔ High Malleability
✔ High thermal conductivity
✔ High electrical conductivity
✔ Good corrosion resistance
✔ Highly recyclable
✔ Antimicrobial
 Applications of Non - Ferrous Materials

❖ Architectural: building fronts, downspouts, flashing, gutters, roofing,

screening, grillwork, bridge bearing plates
❖ Automotive: Gaskets, radiators, heater cores and tanks, automatic high speed
screw machine parts (screws, bolts, fasteners).
❖ Electrical: bus bars, conductivity wire, contacts, radio parts, switches,
terminals, flashlight shells, lamp fixtures, switches, reflectors, screw shells,
socket shells
❖ Hardware: ball floats, butts, cotter pins, nails, rivets, soldering copper, tacks,
eyelets, fasteners, grommets, finish hardware articles (kick plates, lock sets,
push plates, etc.), gears, pinions, beater bars, bellow, bourdon tubing, clutch
disks, cotter pins, diaphragms, fuse clips, fasteners, lock washers, sleeve
bushings, springs, switch parts, truss wire, wire brushes.
❖ Munitions: ammunition components
❖ Plumbing: plumbing accessories, plumbing brass goods
❖ Wire: fasteners, pins, rivets, screws, springs
Applications of Non - Ferrous Materials
 Applications of Non - Ferrous Materials

❖ Electrical conductors
❖ Chemical process equipment
❖ Foils
❖ Decorative finishes
❖ Capacitor (by Panasonic)
❖ Welding wires
❖ Fuel Tanks
❖ Aircraft body
❖ Roofing sheet
❖ Manufacturing beverage cans
❖ Used as filler material
❖ Welding and brazing wire
❖ Forged engine pistons
❖ Architectural applications
Applications of Non - Ferrous Materials
Applications of Non - Ferrous Materials
Applications of Non - Ferrous Materials
Applications of Non - Ferrous Materials
 Ceramic Materials
✔ Ceramics are compounds between metallic and nonmetallic elements
✔ Example: Oxides, Nitrides, and Carbide
✔ Common Ceramics are aluminum oxide (Al2O3), silicon dioxide (SiO2), silicon carbide (SiC), silicon nitride
(Si3N4).
✔ Some of the traditional ceramics, those composed of clay minerals (i.e., porcelain), cement and glass.
✔ Examples of ceramic materials:
✔ All types of glass product including fibers
✔ Cements, line, plaster
✔ Abrasives & some types of cutting of tools
✔ Bricks, tiles, drain, pipes etc..
✔ Refractories for high temperature use
✔ Electrical insulators, Ferro magnetic, semi conductors
 Properties and applications of Ceramic Materials

Properties
✔ Ceramics are in-organic, non-metallic materials that are used at high temperatures
✔ They are generally hard (high hardness) & brittle materials that with stand compression
very well.
✔ They are abrasive resistance, heat resistance & can sustain large compressive loads even at
high temperature
✔ Ceramics are chemically inert even at high temperatures
✔ Good oxidation and reduction resistance at low and high temperatures.
✔ The nature of chemical bond is ionic in character.
✔ Possesses high thermal conductivity, thermal-shock-resistance and thermal capacity
Applications:
✔ Ceramic are used in space industry because of their low weight
✔ Used as cutting tools
✔ Used as refractory materials
✔ Used as thermal insulator
✔ Used as electrical insulator
 Composite Materials
✔ A composite material is a multiphase material.
✔ In which one phase is matrix and another phase is reinforcement (Dispersed phase).
✔ The constituent phases are combined macroscopically to enhance properties.
✔ The constituent phases must chemically dissimilar and separated by interface.
✔ In general composites are divided into two categories
✔ Natural composites: wood (Cellulose is bounded by lignin), Bone (Collagen is
surrounds the Osteons).
✔ Man made composites: Concrete ( Particulate composite of sand, cement with steel
bar as reinforcement)
✔ Matrix is continuous phase and the reinforce is either in the form of particle or in the form
fiber is surrounded by continuous matrix phase.
 Classifications of Composite Materials
Based on Matrix and Reinforcement:
✔ Metal Matrix Composites
✔ Polymer Matrix Composites
✔ Ceramic Matrix Composites
✔ Carbon – Carbon Matrix Composites
 Matrix materials in composite and their functions
Polymer Matrix materials:
✔ Thermosetting Resins: Metal Matrices:
Epoxy
✔ Copper
Unsaturated poly ether
Vinyl Esters ✔ Magnesium
✔ Aluminium
Methyl methacrylate

✔Thermo Plastic Resin:

Nylon 6,6
✔ Titanium
Poly ether ether ketone (PEEK) Ceramic Matrices:
Poly sulphones
✔ Borosilicate's
Functions of Matrix: Poly sulphides
✔ Alumino Silicates
✔ Matrix material may be a metal, polymer or ceramic or Carbon.
✔ Sic, Si3N4
✔ Matrix binds the fibers together.
✔ Zirconia (ZrO2)
✔ Acts as medium by which externally applied load is transmitted and
distributed to fibers. ✔ Al2O3
✔ Protects the fibers form surface damage caused by abrasion or by
chemical reactions.
✔ Matrix materials should have ductile nature.
✔ Should have more adhesive bonding forces.
✔ It should have high stiffness.
✔ Must have corrosion resistance.
 Reinforcement materials in composite

Fiber Reinforced Materials:

Particle reinforced
materials: ✔ Carbon fibers
✔ Glass fibers
✔ Silicon Carbide (SiC)
✔ Boron fibers
✔ Alumina (Al 2O3)
✔ Organic fibers (Polyethylene)
✔ Silica and Silicates (SiO2)
✔ Graphite fibers
✔ Talc , Clays and Mica ✔ Silicon Carbide fibers
✔ Tungsten Carbide (WC) ✔ Silicon Nitride fibers (Si3N4)
✔ Artificial Nicalone fibers
✔ Whiskers
✔ Alumina and Alumina Silicates -
Saffil
 Reinforcement materials in composite

Polymer Matrix materials: Metal Matrices:

✔ Thermosetting Resins: ✔ Copper
Epoxy ✔ Magnesium
Unsaturated poly ether ✔ Aluminium
Vinyl Esters ✔ Titanium
Methyl methacrylate
✔ Thermo Plastic Resin:
Ceramic Matrices:
Nylon 6,6 ✔ Borosilicate's
Poly ether ether ketone ✔ Alumino Silicates
(PEEK) ✔ Sic, Si3N4
Poly sulphones ✔ Zirconia (ZrO2)
Poly sulphides
✔ Al2O3
 Advantages of Composite materials
✔ Low costs compared to metals and alloys (fabrication and raw materials)
✔ Design flexibility (can be designed any complex shapes easily)
✔ Resistance to a wide range of chemical agents
✔ Low weight (densities are less compared to the metals and ceramics)
✔ Durability (composite materials can withstand longer times for wear and abrasive damage)
✔ Electric insulation
✔ As molded dimensional accuracy - tight tolerance, repeatable moldings, low-post mold
shrinkage
✔ High flexural modulus to carry demanding loads, high impact strength, high performance
at elevated temperatures, heat resistance,
✔ Creep resistance
✔ Superior thermal stability
✔ Outstanding electrical insulation, arc and track resistance, ability to quench
 Properties of Composite Materials
Polymer Matrix Composites: Ceramic Matrix Composites:
✔ High specific strength to weight ratio
✔ High material stability against corrosion
✔ High thermal shock and creep resistance
✔ Good electrical and thermal insulation ✔ High temperature resistance
✔ Ease of shaping and economic mass
production ✔ Excellent resistance to corrosion and wear
✔ Attractive optical properties
✔ Impact resistance ✔ Inertness to aggressive chemicals
✔ Improved fatigue strength
Metal Matrix Composites: ✔ High tensile and compressive strength, thus
✔ Higher strength-to-density ratios
✔ Higher stiffness-to-density ratios no sudden failure as compared to
✔ Better fatigue resistance
conventional ceramics
✔ Better elevated temperature properties
(Higher strength, Lower creep rate) ✔ Increased fracture toughness due to
✔ Lower coefficients of thermal expansion
✔ Better wear resistance reinforcement
✔ Higher temperature capability (Fire
resistance) ✔ Lightweight due to reduced density
✔ Higher transverse stiffness and strength
✔ No moisture absorption ✔ High strength retention at elevated
✔ Higher electrical and thermal
conductivities temperatures
✔ Better radiation resistance
 Application of Composite Materials
Aerospace
Thermoset composites are being specified for wings, fuselages, bulkheads, and other applications in
commercial, civilian and military aerospace applications.
Appliance/Business
Thermoset composite are being used in frames, equipment panels, handles and trims in appliances,
power tools, business equipment and many other applications.
Thermoset composites for the appliance industry are used in washers, dryers, refrigerators,
freezers, ranges, ovens, dishwashers for components that include control panels, handles, knobs,
vent trims, side trims, motor housings, kick plates and many others.
Automotive
Composites are now being used in vehicle and equipment applications, including, panels, frames,
interior components and other parts.
Civil Infrastructure
Some composite infrastructure applications include buildings, roads, bridges and pilings.
 Application of Composite Materials
Construction
Thermoset composites are replacing many traditional materials for home and offices
architectural components including fixtures, doors, wall panels, roofing, window frames,
moulding, vanity sinks, shower stalls and even swimming pools.
Corrosive Environments
Used in chemical processing plants, pulp and paper converting, oil and gas refineries and water
treatment facilities. Common applications include fans, grating, tanks, ducts, hoods, pumps and
cabinets.
Electrical
With strong dielectric properties including arc and track resistance, Thermoset components
include substation equipment, microwave antennas, standoffs and pole line hardware and
printed wiring boards. Applications and components include switchgear, motor controls,
standoff insulators, control system components, circuit breakers, arc chutes, arc shields,
terminal blocks, terminal boards, metering devices, bus supports and lighting components.
Marine
With their corrosion resistance and light-weighting attributes, Marine composite applications
include boat hulls, bulkheads and other components for military, commercial and recreational
boats and ships.
 Specific Applications of Composite Materials

✔ Mine Sweeper Hull – Glass fiber reinforced plastic composite is used

✔ Sheet Processing Rolls – Carbon fiber reinforcement composites
✔ Helicopter rotor blade – Carbon fiber reinforced plastic composites
✔ Golf driving club – Boron fiber polymer based composite
✔ Racing bicycle – Duralcan and aerospace metal composite
o Duralcan is Al-Al2O3 composite and aerospace metal is Al-SiC composite
✔ Diesel engine Piston
✔ Micro electronic housing – Kovar material (High Ni steel based
composite)
✔ Gas turbine combustor can
✔ Aircraft brakes – Carbon – Carbon composites (Graphite)
 Smart Materials
✔ Smart materials are engineering materials that can significantly alter one
more of their inherent properties owing to the application of an external
stimuli in a controlled fashion.
✔ External stimulus to which smart materials are sensitive:
▪ Stress
▪ Temperature
▪ Moisture
▪ pH
▪ Electric fields
▪ Magnetic fields
✔ Classification of Smart materials based on field:
• Structural materials- (Stress–Strain Relation)
• Electrical materials – ( R-T relation)
• Bio compatible materials- (Biomimics) - Recognition, analysis & growth characteristics
• Intelligent biological materials - (Biomimics)
• Dynamically tunable materials – versatile
 Specific types of Smart Materials
✔ Shape Memory Alloys: An alloy that “remembers” its original, cold-forged shape. By
heating it returns back to the re-deformed shape.
✔ SMAs are materials which can revert back to original shape & size on cooling by
undergoing phase transformations.
✔ Examples: NiTiNOL (thermal), NiMnGa, Fe-Pd, Terfenol-D (Magnetic) CuZnSi, CuZnAl,
CuZnGa, CuZnSn (actuator)
 Specific types of Smart Materials
✔ Piezoelectric Materials: Materials that produce a voltage when stress is applied.(An
applied mechanical stress will generate a voltage )
✔ Example:Quartz,BaTiO3,GaPO4
✔ The piezoelectric effect describes the relation between a mechanical stress and an electrical
voltage in solids.
✔ In physics, the piezoelectric effect can be described as the link between electrostatics and
mechanics.
✔ An LED is wired to a piezoelectric transducer. The LED briefly lights when the device is
flicked & shows that electricity has been generated by stress and strain.
 Specific types of Smart Materials
Magnetostrictive Material: Magneto striction is a property of ferro magnetic materials that
causes them to change their shape or dimensions during the process of magnetization.
✔ The effect was first identified in 1842 by James Joule when observing a sample of iron.
✔ Ex: Fe, Co, Terfenol – D (US transducers, sonar, sound bug)
✔ Actuators and Sensors: Magnetostrictive transducers - Convert magnetic energy in to
mechanical energy
✔ Vibration Speaker Technology: Using the highest power Smart Material . Install in seconds –
peel and stick - no screws or mounting issues
✔ High quality sound without design compromise. No wires, no boxes, no grilles
 Specific types of Smart Materials
Magneto-Rheological Fluids: A MR fluid is a smart fluid which usually consists of 20-40
percent iron particles, suspended in mineral oil, synthetic oil, water or glycol.
MRF also contains a substance which prevents the iron particles from setting.
When subjected to a magnetic field, the magnetic particles inside increase the fluid's viscosity,
rendering it viscoelastic solid
 Applications of Smart Materials
✔ Smart switches & actuators( NiTi -long life)
✔ Safety device, fuse, alarms (CuZnAl -reliability)
✔ Artificial limbs, blood vessels & muscles - (SM Polyurethane -bio compatibility)
✔ Adhesive tapes/bands ( time bound adhesive property /painless removal/healing property)
✔ Food packaging industry-wrappers( adoptability)
✔ Smart spoons ( Temperature sensitive polymers)
✔ Smart nose & tongue ( recognition characteristics)
✔ Smart clothes ( Adaptive to temperature changes)
✔ An “animated lamp” designed by Romolo Stanco that uses shape-memory alloy to change its shape whenever it‟s
turned on and off. NiTi NOL wire- diameter in mm.
✔ Aircraft which will incorporate "smart materials” that will allow the wings of a craft to change shape for optimal
flying conditions
✔ "Stealth Bombers“ have ferro fluids on their outer“skin” to make them harder to spot with radar.
Than
k You