DEPARTMENT OF MECHANICAL ENGINEERING
FOUNDATION OF MECHANICAL ENGINEERING 2023
Unit I UNITS AND MEASUREMENTS 6
Introduction – Science & Technology –Units and dimensions – definition –
fundamental quantities – definition and their SI units, symbols – Derived physical
quantities – Dimensional formula for length, mass and time, SI unit multiples and
submultiples and prefixes of units.
Measurements: Need & limitations of measuring instruments, least count,
types of measurement, – screw gauge – Vernier calliper- Applications into
industries. Errors in measurement (systematic and random), absolute error,
relative error, error propagation (no derivation) –precautions to avoid systematic
and random errorsEngineering applications.
Physical quantities: velocity, momentum, acceleration, force, impulse, work,
energy and power, Horsepower, watt, Calorie and Joule – Conversions.
Practical: 6
Ex. 1 SCREW GAUGE: Using Screw Gauge: (i) Find the thickness and volume of
given gauge wires by measuring its length and diameter and error estimation (ii)
Find the volume of the glass plate by measuring its thickness and area
Ex. 2 VERNIER CALIPER: Using Vernier Caliper: (i) Find the volume of a given
hollow and solid cylinder by measuring its length and diameter (ii) Find the volume
of a given rectangular block by measuring its length, breadth and thickness and
error estimation
Unit II MECHANICS - STATICS 6
Scalar and vector quantities: Definition and examples – Resolution of vector
into two perpendicular components – Concurrent forces & coplanar forces:
Examples – Resultant and Equilibrant force – Triangle and Parallelogram law for
two forces: Statement only (no derivation), Examples – Lami’s theorem – statement
and explanation – Experimental verification of parallelogram of forces and Lami’s
theorem – Engineering applications - Moment of force, Couple – Principle of
moment – Determination of mass of the given body
Practical : 6
Ex. 3 VERIFICATION OF LAMI’S THEOREM: Verification of parallelogram and
Lami’s theorem for concurrent forces
Ex. 4 PRINCIPLE OF MOMENT: Using the principle of moment, determine the
unknown mass of the given object
Unit III MECHANICS - DYNAMICS 6
Newton laws, kinematic equations – Examples (horizontal, freely falling,
vertically thrown) – Projectile motion (qualitative discussion) – Circular motion –
angular velocity – period – frequency – relation between linear and angular velocity
– centripetal and centrifugal force: application of centripetal and centrifugal forces
(working of a centrifuge device) - Simple harmonic motion – amplitude – frequency
– period – Simple pendulum – Acceleration due to gravity
Practical : 3
Ex. 5 SIMPLE PENDULUM: Determination of acceleration due to gravity using
simple pendulum
Unit IV INTRODUCTION AND BASIC CONCEPTS OF THERMODYNAMICS 6
System and surrounding - types of system; thermodynamic properties
-Intensive vs. extensive properties, state of a system, path and process.
Thermodynamic Equilibrium; Zeroth law of thermodynamics, First Law of
Thermodynamics, Second Law of Thermodynamics,
Practical : 9
Ex. 6 CALORIMETER: Determination of specific heat of a metal using calorimeter
Ex. 7 THERMOCOUPLE: verification of the relation between thermo emf of a
thermocouple and temperature difference between two hot junctions.
Ex. 8 Verification of First and second law of Thermodynamics
Unit V HEAT TRANSFER 6
Introductory concepts and definitions: Modes of heat transfer: Basic laws
governing conduction, convection, and radiation heat transfer; Applications in
various systems
Practical : 6
Ex. 9 CONDUCTION - To find the thermal conductivity of a material by the two
slabs guarded hot plate method.
Ex. 10 CONVECTION - To determine the overall heat transfer coefficient at the
surface of a given vertical metal cylinder by the natural convection method.
References:
1. XIth standard Tamilnadu State Board Physics Text Book, 2023 edition,
Textbook Corporation Tamilnadu
2. [Link], Concepts of Physics Vol 1 & Vol 2, Bharathi Bhavan Publishers,
1st edition, 2021
3. Stephen R. Turns, Thermodynamics: Concepts And Applications,
Cambridge University Press, 2006.
4. Babu, V., Fundamentals of Engineering Thermodynamics, 2nd Edition, Ane
Books, 2019.
5. Sonntag, R. E, Borgnakke, C. and Van Wylen, G. J., Fundamentals of
Thermodynamics, 6th Edition, John Wiley and Sons, 2003.
QUANTITATIVE APTITUDE AND CORE NUMERICALS 3 1 0 4
UNIT 1: Number Systems & Simplifications with Industrial Applications 12
LCM and HCF (Prime factor method, Division method) -Decimal and
Fractional representations - Rational vs Irrational numbers - Surds and Indices -
Significant figures, Scientific notation - Estimations and Approximations using
BODMAS
Mechanical Engineering Applications:
● Calculating gear ratios, screw thread pitches
● Measuring work piece dimensions with decimal accuracy
● Electrical ratings using scientific notation
Hands-on Activities:
● Practical rounding: Convert caliper readings (e.g. 26.374 mm) to nearest
standard sizes
● Mini-project: Create a metric conversion chart using index laws
● Workshop task: Match gear teeth using LCM of input/output RPM
UNIT 2: Applied Arithmetic & Algebra in Mechanical Systems 12
Percentages (loss/gain, efficiency) - Ratios and Proportions (direct, inverse,
compound) - Time & Work (efficiency methods, pipes and cisterns) - Speed, Time,
Distance (relative speed, average speed) - Simple and Compound Interest - Linear
equations and basic algebraic manipulations
Mechanical Engineering Applications:
● Estimating fuel efficiency (km/l and % increase/decrease)
● Work allocation in batch manufacturing
● Pulley and belt system speed analysis
● Costing and finance of tools & machine parts
Hands-on Activities:
● Workshop scenario: Calculate job completion time with 2+ workers on lathe
machines
● Problem-solving lab: Build real-time pulley systems and measure speed
ratios
● Finance case-study: Calculate compound depreciation of a milling machine
UNIT 3: Logical & Data Reasoning for Mechanical Operations 12
Number series, missing terms, patterns - Basic coding-decoding and logic
tables - Directional logic, blood relations (only logic flow) - Data interpretation:
Tables, pie charts, line graphs - Venn diagrams, binary logic, truth tables
Mechanical Engineering Applications:
● Understanding sequence in CNC programming
● PLC ladder logic understanding
● Interpreting maintenance logs or quality data
Hands-on Activities:
● Logic workshop: Build mechanical troubleshooting flowchart (fan not
working, lathe fault)
● Data lab: Use Excel to interpret factory production data and draw graphs
● Group activity: Direction sense game using real workshop map layout
UNIT 4: Core Calculus & Algebra for Mechanical Systems 12
Functions and Graphs (polynomial, exponential) - Limits (basic limit theorems) -
Differentiation: Product, quotient, chain rule - Applications: Velocity, acceleration,
Maxima-Minima
Integration: Area under curve, volume of revolution
Matrices: Addition, multiplication, inverse - Solving systems using Cramer’s Rule
and Matrix Inversion
Mechanical Engineering Applications:
● Velocity & acceleration in crankshaft motion
● Area estimation in heat exchanger design
● Force resolution in truss using matrix methods
Hands-on Activities:
● Excel activity: Plot velocity-time graph and compute area (displacement)
● Workshop math: Measure radius of curved parts and estimate surface area
● Math lab: Solve force system in truss using matrices (2×2)
UNIT 5: Geometry & Trigonometry in Machine Layouts 12
Cartesian coordinate system - Straight lines: slope, intercepts - Circle:
center-radius form, tangent - Trigonometric identities, angle transformation -
Heights & Distances: Angle of elevation/depression - Inverse trigonometric
functions
Mechanical Engineering Applications:
● Blueprint and CAD drawing analysis
● Inclined planes and force resolution
● Cam profile and circular part analysis
● Angular measurement with sine bar and vernier bevel protractor
Hands-on Activities:
● CAD Lab: Draw mechanical components using line and arc commands with
coordinates
● Metrology Task: Measure taper angle using sine bar and height gauge
● Field Activity: Use clinometer to measure workshop roof height using
trigonometry
References:
1. S. Aggarwal Quantitative Aptitude for Competitive Examinations, [Reprint
2017 ed.]
2. Rajesh Verma , Fast Track Objective Arithmetic, Arihant Publications India
limited, 20 Apr 2018
3. Higher Engineering Mathematics, BS Grewal, Khanna Publications, 42nd
Edition
4. Kandasamy, P., Thilagavathy, K., and Gunavathy, K., “Engineering
Mathematics”, Volumes II & III (4th Revised Edition), S. Chand & Co. New
Delhi, 2001
Industrial Chemistry with Mechanical Applications 2 2 0 3
Unit 1: Water Chemistry (Boiler & Industrial Use) 12
● Sources and types of impurities in water (1 hr)
● Hardness: Causes, units, types (1 hr)
● Boiler troubles: Scales, sludges, priming, foaming, caustic embrittlement (2
hrs)
● Water softening: Lime soda, zeolite, ion-exchange (2 hrs)
● RO, desalination, and their relevance in industry (1 hr)
● Chemistry of cooling water treatment (1 hr)
Practical/Hands-on (4 hrs)
● EDTA titration for hardness of raw and softened water
● Visit/demo of water treatment plant (or boiler simulator demo)
● Design of mini water treatment model (concept-based)
Unit 2: Fuels and Lubricants 12
● Classification of fuels: solid, liquid, gaseous (1 hr)
● Fuel characteristics: calorific value, ignition temp, flash & fire point (2 hrs)
● Modern fuels: Biofuels, hydrogen, LPG, CNG, and green fuels (2 hrs)
● Introduction to lubrication: purpose and importance (1 hr)
● Types of lubricants: solid, semi-solid, liquid, synthetic (2 hrs)
● Properties: viscosity, flash/fire point, oiliness, acid value (2 hrs)
Practical/Hands-on (3 hrs)
● Bomb calorimeter demonstration for solid/liquid fuel
● Analysis of calorific value and fuel efficiency
● Measure viscosity using Redwood viscometer
● Ball bearing friction test with different lubricants
● Bio-lubricant preparation (from coconut/castor oil)
Unit 4: Corrosion and Protection 12
● Corrosion basics: definition, electrochemical theory (2 hrs)
● Types: uniform, pitting, crevice, intergranular, stress corrosion (2 hrs)
● Factors affecting corrosion: pH, temperature, moisture, metal (2 hrs)
● Prevention: coatings, anodizing, galvanizing, cathodic protection (2 hrs)
● Corrosion in machine parts and pipelines (1 hr)
Practical/Hands-on (3 hrs)
● Rusting experiment (steel nail in saltwater + galvanic protection)
● Metal coating samples: painted vs galvanized vs anodized
● Visit to college workshop for corroded parts documentation
Unit 4: Engineering Polymers & Composite Materials 12
● Basics of polymers: thermoplastics vs thermosets (1 hr)
● Engineering polymers: nylon, PTFE, PVC, Bakelite (2 hrs)
● Composites: fiber-reinforced plastics, metal-matrix composites (2 hrs)
● Adhesives, sealants in mechanical assemblies (2 hrs)
● Nano-materials and smart materials (1 hr)
Practical/Hands-on (4 hrs)
● Identification of polymers by density and heat test
● Heat resistance comparison of plastics (gear casing vs fan blade)
● Composite sample analysis (e.g., brake pad materials)
● Adhesive joint strength test (wood, metal)
Unit 5: ENVIRONMENTAL CHEMISTRY 12
● Air pollution – Air pollutants (SO2, H2S, HF, CO and Dust) Sources and
Harmful effects - Formation of Acid Rain -Green House Effect – Causes –
Ozone layer depletion - Global warming- Control of Air Pollution.
● Solid Waste – Definition – Problems – Types of Solid waste methods of
Disposal – Land fill and Incineration
● Recycling – Definition – Examples – Advantages of Recycling (Basic ideas)
Green Chemistry Definition – Goals of Green Chemistry
Practical/Hands-on (4 hrs)
● Crystallization of copper sulphate and identification of ion
● Decolorization of clayey water using sand bed.
Tools Required in Lab/Workshop
● Viscometer (Redwood or Saybolt)
● Bomb calorimeter
● Lubricant testing rig
● EDTA titration kits
● Mini boiler simulation kit
● Rust testing box
Suggested Learning Materials
● Applied Chemistry for Engineers– B.S. Chauhan
● Engineering Chemistry* – Jain & Jain
● Industrial manuals: Indian Boiler Board, IOCL, SKF Lubricants Guide
