Government of Karnataka

Department of Technical Education

C-25 Diploma in Mechanical Engineering

Scheme of Studies
(Effect from the AY 2025-26)
 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION
Curriculum Structure
I Semester Scheme of Studies – Mechanical Engineering
CIE Theory SEE Practice SEE

Total Contact
Hours/week
Department

Hours per week

Teaching

Marks Marks Marks

Credits
Sl. Total
Course Code Course Name
No. Marks
L T P Max Min Max Min Max Min

Integrated Courses

1 SC 25SC11I Engineering Mathematics-I 4 0 4 8 6 50 20 50 20 - - 100

Essential English
2 ENG 25EG01I 4 0 4 8 6 50 20 - - 50 20 100
Communication

Computer Aided Engineering

3 EE 25ME01I 3 0 4 7 5 50 20 - - 50 20 100
Drawing

Mechanical Engineering
4 ME 25ME11I 4 0 4 8 6 50 20 50 20 - - 100
Practices-I
Audit Course
-
5 ME 25ME12T Environmental Sustainability 2 0 0 2 2 50 20 - - - 50

Personality Students are expected to engage in any one of these activities from 1st semester to 6th semester
6 NCC/NSS/YOGA/SPORTS…
Development (No Credits)
-
Total 17 0 16 33 25 250 - 100 100 - 450
 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION

Program Mechanical Engineering Semester I

Course Name Mechanical Engineering Practices-1 Type of Course Integrated
Course Code 25ME11I Contact Hours 104 hrs/Sem

Teaching Scheme L: T:P – 4-0-4 Credits 6

CIE Marks 50 SEE Marks 50 (Theory)

1. Rationale:
Engineering Materials play an important role through conventional and advanced
materials leading to technological advances. Over a period of time, a lot of research has been
done to develop materials that transformed civil society. Understanding the structure-property
relationship and selecting the right material for a given application is vital in the modern
customer-driven market. Therefore, a Diploma engineering student must be conversant with the
properties, composition and behavior of materials from the point of view of the product's
reliability, sustainability and performance. The study of engineering materials will help the
students to understand engineering subjects where the emphasis is laid on the application of
these materials. Understanding the basics of Theory of Machines is essential for mechanical
engineers to design, develop, and optimize mechanical systems, mechanisms, and machines.

Diploma Engineers are responsible for supervising production processes to achieve

production targets and for optimal utilization of resources. For this purpose, knowledge about
various manufacturing processes is essential. This requires training the students with a focus on
Fitting and Welding, operations provides essential skills, knowledge, and experience about the
various manufacturing processes. Hence this integrated course is introduced to provide strong
foundation in practical skills, safety awareness, and problem-solving abilities essential for
success in mechanical engineering and related fields.

2. Course Outcomes: At the end of the Course, the students will be able to:
CO-01 Measure the dimensions of a work piece as per the given drawings
CO-02 Select the materials for a specified application
CO-03 Select transmission system for the specified application
CO-04 Perform basic carpentry, Fitting and metal joining process
Department of Technical Education, Government of Karnataka 3
3. Details of Course Content
WEEK CO PO Theory Practice
Introduction to Mechanical Engineering,
 Measurement of linear
scope of Mechanical Engineering and
dimensions using Vernier
Carrier’s opportunities for Mechanical calipers
Engineers  Measurement of height using
 Fundamental Units – Definition and Height gauge
units of Length, Mass, Time &  Measurement of outside
1 1 -
Temperature in CGS, FPS, MKS & SI diameter by using screw gauge
Units with conversions.  Measurement of inside diameter
 Derived Units – units of Area, Volume, using inside caliper
Density, Velocity, Acceleration, Force,  Measurement of angle by using
Work, Energy Power in CGS, FPS, MKS & bevel protractor and sine Bar
SI Units with conversions. (Formulae &
Simple numerical examples)
Material Science
Classification of Engineering Materials
 Mechanical Properties - Elasticity,
Plasticity, Malleability, Ductility,
Brittleness, Strength, Toughness,
Hardness, Stiffness, Resilience,
Creep, Endurance, Fatigue &
Machinability
 Thermal Properties - Thermal
conductivity, Specific Heat, Thermal The students shall prepare the chart
Expansion, Thermal Diffusivity, showing the Mechanical, Thermal,
Thermal Fatigue, Thermal Shock, & Electrical, Chemical and Magnetic
Melting Point properties Engineering Materials
2 2 1,2,4  Electrical Properties – Resistivity,
Conductivity, Dielectric Strength,
Temperature Coefficient of
Resistance
 Chemical Properties- Reaction with
Oxygen, Reaction with water,
Reaction with Acid, Reaction with
Base
 Magnetic Properties- Diamagnetic
material, Paramagnetic materials,
Ferromagnetic materials, Magnetic
permeability, Magnetic Flux Density,
Magnetic Field Strength, Magnetic
Moment, Magnetization, Magnetic
susceptibility

Department of Technical Education, Government of Karnataka 4

 Ferrous Materials
 Cast Iron- Types of cast iron- Grey,
White, Malleable. Properties,
composition and applications of cast
iron
 Steel –Types, Designation of steel,
Types -Plain Carbon Steel- Low (0.15-
0.25%C), Mild (0.25%C), Medium (0.25-
0.65%C), High Carbon (0.65-1.5%C),
Properties, composition and
applications of steel

Alloy Steel- Tool Steel, Tungsten steel,
Stainless-Steel, High-Speed Steel,  Display the different components
3 2 1,2,4 Properties, composition and made up, of cast iron, steel and
applications of alloy steel alloy steel
This concepts shall be thought by Using the
 The students shall identify
components made up of cast iron, steel and
minimum 10 components and
alloy steel as teaching aids, such as Cast
prepare the chart showing the
Iron:Rails in Railways, Machine tool beds,
components pictures, its
Grey CI - Flywheels, Man-hole Cover,
material, their properties and its
Sewage pipes. Pump Casing; White CI- Ball
application
Mills, Wear Plate, Marine Pump Impeller,
Malleable- Gear Housing, Clamps Fixtures,
Wrench and Pliers.
Steel: Welding Electrodes, Chassis, car
body, gears, axels, Shafts, Fasteners,
exhaust, springs, axles and laminated
springs; Machine Structure, Cutting Tools,
Sheet metals etc
Non-Ferrous Materials
Properties, composition and applications of
 Aluminum and Aluminum Alloys –  Display the different components
Duralumin, Y-Alloy, Magnesium, made up of Aluminum &
Hindalium. Aluminum Alloys, Copper &
Copper Alloys, Zinc Based Alloys,
 Copper and Copper Alloys - Brass,
Nickel Based Alloys
Bronze, Gun Metal, lead, Tin. Bearing
 The students shall identify
4 2 1,2 Metals. minimum 10 components and
 Zinc Based Alloys – Solder, German prepare the chart showing the
silver; components pictures, its
material, their properties and its
 Nickel Based Alloys – Inconel, Monel
application
metals.
This concepts shall be thought by Using the
components made up of Aluminum &
Aluminium Alloys, Copper & Copper Alloys,
Zinc Based Alloys, Nickel Based Alloys as

Department of Technical Education, Government of Karnataka 5

 teaching aids, such as Food Wrapping,
Rivets, Connecting Rods, Aircraft engine
Parts, utensils, Electrical Connectors, tubes
used in refrigerators, Water Pump parts,
Bearings, bushes, Gun Parts, bells, Solders,
propellers., Gun Parts, bells, Solders,
propellers. Heat Exchangers, Cutting Tool
Inserts

Non- Metals
Properties, composition and applications of
 Polymers: Thermoplastics (PE, PLA,
PVC, Nylon, ABS), thermosetting
polymers (Bakelite, Epoxy) and  Display the different components
Biodegradable Polymers. made up of Polymers, Ceramics,
Composites
 Ceramics- Types - Oxides, Carbides,
 The students shall identify
properties and applications. minimum 10 components and

Composites- Types (GFRP, CFRP), prepare the chart showing the
properties and applications. components pictures, its
5 2 1,2,4
This concepts shall be thought by Using the material, their properties and its
components made up of Polymers, application
Ceramics, Composites as teaching aids,
such as Plastic bags, Water bottles, Water
mugs & buckets, Plumbing pipes, Spectacle
frame, Tires, Ropes, Electric switch board,
Fan, Shoes, Rain coats, Biodegradable
polymers, Spark plug, Wash Basin, Artificial
teeth, Electric Resistors and Fuse Holder,
video of Wind turbine blades, Aircraft
wings, Bicycle Frame etc

Carpentry Practice
 Explain and show the different Types of wood, their Properties and
applications.
 Demonstrate the Safety precautions to be followed in Carpentry shop
 Demonstrate the tools and equipment’s used in Carpentry shop
 Prepare the model as per give drawing (Given models are only suggestive)
6 4 4  Check the dimensions using measuring instruments as per the given drawing.

Department of Technical Education, Government of Karnataka 6

 Fitting Practice
 Demonstrate the Safety precautions to be followed in Fitting shop
 Demonstrate the tools and equipment’s used in Fitting shop.
 Demonstrate the different operations like chipping, filing, drilling, tapping,
sawing, cutting etc
 Prepare Fitting job as per given drawing (Given models are only suggestive)
 Check the dimension using measuring instruments as per the given drawing

7 4 4

Basics of Kinematics of Machines

 Kinematic link or Element- Types of
links Kinematic pair–Types.
 Types of constrained Motions,
Kinematic chain- Definition of Machine,
Structure and Mechanism.
 Inversions-Types of Kinematic Chains, Practice
8 3 1,2,3 Four Bar Chain, Beam Engine. Students shall demonstrate the simple
This concepts shall be thought by Using mechanisms using models
the models of different applications of
kinematics such as Piston and cylinder,
drawer slides, hinged joints, robotic arm
joints, Ball-and-socket joints (hip,
shoulder), Nut and bolt, lead screw in a
machine tool etc as teaching aids
Inversions and Kinematic Chains
 Single Slider Crank Chain, Crank and
Slotted Lever. Practice
9 3 1,2,4 Students shall demonstrate the simple
 Quick Return Motion Mechanism
mechanisms using models
 Double Slider Crank Chain, Scotch yoke
mechanism,

Department of Technical Education, Government of Karnataka 7

  Pantograph
This concepts shall be thought by showing
the different inversions of kinematic chain
used in shaping, cutting machines, slotting
machines, rotary internal combustion
engines, Reciprocating engines and control
valve actuators as teaching aids
Transmission System
Classification of Transmission system
Belt Drives
 Types of Belt Drives,
 Length of belt drive in open and cross belt drive
 Concept of Velocity Ratio, Slip and Creep,
 Material used for Belts
Rope Drives
10 3 1,2,4  Applications of Rope drives
Chain Drives
 Applications of chain drives
This concepts shall be thought by showing the different applications of belt drives
in Flour Mills, Lathe Machines, Compressors, Vehicle Engines, Blowers, Washing
machines, Rope drives in cranes, elevators etc. as teaching aids
 Simple Problems on Velocity Ratio, Slip and Power Transmitted by Belt (Flat &
V-Belt
 Simple Problems on calculating number of Ropes required to a transmit power

Gears and Gear Trains

 Gears Drives– Introduction, Classification, Gear Terminology
 Gear Trains – Introduction, Types, Simple & Compound Gear Trains
 Reverted and Epicyclic Gear trains
11 3 1,2,4 *Use different applications of gear trains in Lathe Machines, Milling Machines,
Gear boxes, etc. as teaching aids

 Simple Problems on Gear Trains

 Determine the velocity ratios of belt drives/gear drives used in
Lathe/Drilling/Shaper/Planer/Grinding machines in the workshop
Metal Joining processes
Classification of Joining Process - Temporary and Permanent joining processes.
Fasteners
12 4 1,4  Rivets, Bolts and Nuts and types.
Welding
 Classification of welding process
 Arc welding process,
Department of Technical Education, Government of Karnataka 8
  Arc welding electrodes
 arc welding equipment’s.
 Explain the TIG (GTAW) and MIG (GMAW) welding.
 Explain the defects in arc welding process
Practice
 Demonstrate the Safety precautions to be followed in arc welding
 Demonstrate the tools and equipment’s used for arc welding
 Demonstrate the arc welding process
 Practice the arc welding process as per given drawing (Given models are
only suggestive)

Fillet Corner joint on MS plate 10 mm thick in

flat position

Fillet Butt joint on MS plate 10 mm thick in flat

position

Fillet T-Joint on MS plate 10 mm thick in flat

position
Fillet Lap Joint on MS plate 10 mm thick in flat
position
 Check for the defects in welding process
Soldering and Brazing
 Explain the Principles of Soldering and Brazing Processes,
 Fillers, heating methods
 Applications
Practice
 Practice the brazing process as per given drawing (Given models are only
suggestive)

Gas welding
 Explain the CO2 and Oxy-Acetylene gas welding process
 Explain the different types of gas welding flames
Practice
13 4 4  Demonstrate the Safety precautions to be followed in gas welding process
 Demonstrate the tools and equipment’s used for gas welding
 Demonstrate the gas welding process with different flames
 Practice the gas welding process as per given drawing (Given models are
only suggestive)
Department of Technical Education, Government of Karnataka 9
  Straight line beads and multi-layer practice on M.S. Plate 10 mm
thick in Horizontal position.
 Structural pipe welding butt joint on MS pipe Ø 50 and 3mm WT in
1G position
 Check for the defects in welding process

4. References:
Sl.
Author Title of Books Publication/Year
No.
Woodhead Publishing Limited,
1. J. W. Martin Materials for Engineering
3rd Edition, 2006
Material Science and Wiley Publications, 10th
2. William D. Callister Jr.
Engineering Edition, 2020
V K Manchanda, GBS Materials science and Khanna Publishers, 1st Edition,
3.
Narang, J S Narang Metallurgy 2021
R.K. Rajput Materials science and S.K. Kataria& Sons, 5th Edition
4.
Engineering 2016, Reprint 2024
Charotar Publishing house,
5. Rangwala Engineering Materials
43rd Edition, 2019
6. C P Sharma Engineering Materials PHI Learning, 2004
Mc Graw Hill Publications, 4th
7. S S Rattan Theory of Machines
Edition, 2019
8. R S Khurmi Theory of Machines S Chand Publication, 2005

9. J S Brar, R K Bansal Theory of machines Firewall Media, 2004

Elements of Mechanical
10. K R Gopalakrishna 2019
Engineering
S. K. Hajra Choudhury, Elements of Workshop
Media Promoters & Publishers
11 A. K. Hajra Choudhury, Technology Vol-I
Private Limited - 2008
Nirijhar Roy Manufacturing Processes
Elements of Workshop
S. K. Hajra Choudhury, Media Promoters & Publishers
12 Technology Vol-II
Nirijhar Roy Private Limited - 2010
Machine Tools
13 R. B. Gupta Workshop Practice Stay Prakashan - 2024
Computech Publications
14 G. S. Sethi Welder Trade Tutorial
Limited - 2022
G. S. Sethi Computech Publications
15 Fitter
Balbir Singh Limited - 2021

Department of Technical Education, Government of Karnataka 10

5. CIE Assessment Methodologies

Sl.N Test Duration Max

CIE Assessment
o Week (minutes) Marks
1. CIE-1 Theory Test 4 90 50

2. CIE-2 Practice Test 7 180 50

Average of all
3. CIE-3 Theory Test 10 90 50 CIE=50 Marks
4. CIE-4 Practice Test 13 180 50

CIE-5 Portfolio evaluation of all practices

5 1-13 50
and Activities through Rubrics

Total 50 Marks

6. SEE - Theory Assessment Methodologies

Sl.N Duration Max Min Marks to

SEE – Theory Assessment
o (minutes) Marks Pass

1. Semester End Examination-Theory 90 50 20

7. CIE Theory Test model question paper

Program Mechanical Engineering Semester- 1

Course Name Mechanical Engineering Practices - I Test I

Course Code 25ME11I Duration- 90 min Marks-50
Name of the Course Coordinator:
Note: Answer any one full question from each section. Each question carries equal marks.
Q. No Questions CL CO Marks
Section - 1
a) A cylinder tank has a volume of 2 m3. How many liters of liquid can it hold?
b) Identify the key properties required for materials used in Bearings.
c) Suggest essential properties used for Shafts in machinery. 5X5 =
1 Apply CO1
d) Identify the properties required for the materials used in manufacturing of 25
Springs.
e) Recognize properties should materials for Bolts and fasteners possesses.
a) The density of a metal is 7800 kg/m3. Convert this density to gm/cm3
b) Suggest the key properties considered when selecting cast iron for sewage
pipelines and fittings. Recommend a suitable type of cast iron.
5X5 =
2 c) Identify the desired properties for laminated springs in automobile Apply CO1
25
suspension systems and recommend the appropriate type of carbon steel
d) Identify the significant properties required for Kitchen utensils made from
Stainless Steel. Suggest suitable Stainless steel.
Department of Technical Education, Government of Karnataka 11
 e) Suggest the critical engineering properties needed for the manufacturing of
machine beds and recommend a suitable metal.
Section - 2
a) Propose the appropriate non -ferrous metals for tubes used in refrigerators
and justify your choice based on the required properties.
b) Aluminum alloys are preferable choice in Aerospace industries. Highlight its
Advantages and Disadvantages.
c) Propose the appropriate non -ferrous metals for food packing and justify 5X5 =
3 Apply CO1
your choice based on the required properties. 25
d) Which non -ferrous metal is suitable for making bearings and bushes and
why is it chosen based on its properties.
e) Which non -ferrous metal is suitable for making cutting tool inserts and why
is it chosen based on its properties.
a) Which polymer is suitable for water bottles and why are they preferred over
metal bottles?
b) A wash basin can be made of a metal as well as a ceramic. Appreciate the use
of ceramics over metals. Suggest a suitable ceramic material.
5X5 =
4 c) Appreciate the suitability of composite material for aircraft wing application Apply CO1
25
and suggest suitable composite material.
d) Which nonmetal is used the production of Spark plugs. Highlight its
properties.
e) Which nonmetal is used the production of Gun parts. Discuss its properties.
Note for the Course coordinator: Each question may have two, three, four and five subdivisions. Optional
questions in each section carry the same weightage of marks, cognitive level and course outcomes.

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

8. CIE Practice Test model question paper

Program Mechanical Engineering Semester I

Course Name Mechanical Engineering Practices - I Test II
Course Code 25ME11I Duration 180 min Marks 50
Name of the Course Coordinator:
Note: Answer any one full question from the following
Questions CO Marks
1. a. Explain the Safety precautions used in Carpentry
shop.
b. Prepare the model as per the dimensions given below.

2. a. Explain the Safety precautions used in Fitting 10+40 = 50

4
shop. Marks
b. Prepare the model as per the dimensions given
below.

Department of Technical Education, Government of Karnataka 12

 Scheme of Assessment -Q No.1 & 2 -
a) Identify safety outfits, usage of appropriate safety method - 10 Marks
b)
 Listing of tools & operations required for performing job – 10 Marks 50 Marks
 Marking of job - 05 Marks
 Operations performed - 20 Marks
 Finishing and Dimensional accuracy of the job- 05 Marks

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

9. Suggestive Activities for Tutorials:

 The students shall do minimum of one suggested activities

 List is an Example and not inclusive of all possible activities of the course.
 Student and Faculty are encouraged to choose activities that are relevant to the topic.

[Link]. Suggestive Activities for Tutorials

01 Develop the working model of Single Slider crank mechanisms.
02 Develop the working model of Double slider crank lever mechanisms
03 Develop the working model of Quick return mechanisms
04 Develop the working model of Crank and slotted lever mechanisms

05 Develop the working model of Four bar chain mechanism

10. Rubrics for Assessment of Graded Exercises(Qualitative Assessment)

Need
Sl. Unsatisfactory Satisfactory Good Excellent Student
Improvement
Dimension
No. Score
(0-5) (6-10) (11-15) (16-20) (20-25)
Adequately Mostly Fully prepared
Lacks several
Not prepared prepared but prepared with all necessary
1 Preparation important 20
at all missing key with minor materials and
materials or tools
items omissions tools
Some Minor Test or task
Major errors inconsisten errors in performed
Execution/Im Task not
2 affecting results cies or execution, flawlessly with 20
plementation executed
or functionality inaccuracie but overall precision and
s present effective accuracy
Poor quality, Acceptable High-quality
No quality Good
Quality of major flaws quality with output, meets or
3 demonstrate quality with 15
Work impacting noticeable exceeds
d minor flaws
functionality defects standards
Mastery of tools
No proper Basic use of Good use of
Use of Weak use of and techniques
tool use tools, some tools, minor
4 Tools/Techniq tools, significant demonstrated 20
demonstrate inefficiencie issues with
ues risks noted safely and
d s technique
effectively
Major Major sections Some Most All required
Practical
sections are are missing or sections are sections are sections are
5 Record 25
not poorly included, complete included and
submission
addressed. addressed. but lack with minor thoroughly
Department of Technical Education, Government of Karnataka 13
 detail. omissions. detailed.

Average Marks=(20+20+15+20+25)/5=20 20
Note: Dimension and Descriptor shall be defined by the respective course coordinator as per the
activities

11. SEE–Model Theory Question Paper

Program Mechanical Engineering Semester I

Course Name Mechanical Engineering Practices - I Marks 50
Course Code 25ME11I Duration 90 Min
Note: Answer any one full question from each section. Each full question carries equal marks.
Cognitive
Q No Questions CO Marks
Levels
Section -1
a) Identify the key properties necessary for materials utilized in the
fabrication of car bumpers and dashboards 5+5=
1 Apply CO1
b) Calculate the Pressure exerted when the Force of 150N is applied 10Marks
over an area of 0.5m2. Express your answers in kPa.
a) Identify the suitable metal used in the production of Gear
Housing of an automobile. Mention its properties 5+5=
2 Apply CO1
b) A force of 100N applied to an object of area 4m2. Calculate the 10Marks
stress developed in the object.
Section -2
a) Select the suitable nonferrous metal/alloy for the production of
sheet metals. Justify with its properties. 5+5=
3 Apply CO1
b) Identify the Nickel alloy used in the production of Impellers. 10Marks
Justify the selection based on its properties.
a) Metals are used in high strength applications as compare to
Nonmetals. Highlight other possible comparison between metals
5+5=
4
and non-metals. Apply CO1
10Marks
b) Identify the suitable nonmetal for the production of Bicycle
Frame. Justify the selection by mentioning its properties.
Section -3
a) Select the type of belt used for connecting two pulleys with center
distance of less than 5m and highlight its advantages over other
belts. 5+5=
5 Apply CO2
b) Identify and briefly explain the type of flat belt drive used in – 10Marks
Flour Mills
- Washing machines
a) Identify and briefly explain the type of gear drives used for the
following applications
- When the axes of the shafts are parallel
5+5=
6 - When the axes of the shafts are Perpendicular Apply CO2
b) Two gear wheels having 80 teeth and 30 teeth mesh with each
10Marks
other. If the smaller gear wheel runs at 480 rpm, find the speed of
the larger wheel.
Section -4

Department of Technical Education, Government of Karnataka 14

 a) Identify and justify the type of kinematic pair used in the following
applications.
5+5=
7 - Piston and cylinder Apply CO3
- Nut and Bolt 10Marks
b) Discuss the components of a four-bar chain and their functions.
a) Identify the mechanism used in Shaping machine. Briefly explain
with neat sketch. 5+5=
8 b) Identify the mechanism used in Reciprocating engines. Briefly Apply CO3
10Marks
explain with neat sketch.
Section -5
a) Identify the type of fastener used in the assembly of Bus body
and Rail coaches. Justify why it is preferred over other fasteners.
5+5=
9 b) Discuss the importance of temporary and permanent joining Apply CO4
processes. Provide examples of applications where each type
10Marks
would be preferred.
a) Identify the welding technique used for thin materials. Highlight
its principle of working. 5+5=
10 b) Suggest the suitable technique used to join the materials when the Apply CO4
10Marks
operating temperature is below 450°C. Highlight its applications.

13. Equipment/softwarelistwithSpecificationforabatchof30students

Sl.N
Particulars Specification Quantity
o.
Fitting shop
01 Flat file 14″ rough bastard file 30
02 Try square 6″ 30
03 Triangular file 10″ rough 30
04 Hack saw frame 12″ 30
05 Center punch Standard size 30
06 Ball peen hammer 11/2 lbs 30
07 Flat chisel 6″ 30
08 Smooth file 10″ flat 30
09 Bench vice 8″ 30
10 Leg vice 6″ 10
11 Power hack saw Standard size 01
12 Bench grinding Standard size 01
13 Tap set and die set Upto1″ 01
14 Vernier caliper 0-300 mm 10
15 Spring divider Standard size 20
16 Steel scale 0-300 mm 30
17 Vernier height gauge 0-300 mm 01

Department of Technical Education, Government of Karnataka 15

 18 Surface plate 2 x 3 feet 01
19 Number punch Standard size 01
20 Anvil Standard size 10
21 V block Standard size 02
Welding shop
01 Arc welding transformer Upto 300 Amps 03
02 Welding shield Standard size 20
03 Ball peen Hammer 11/2 Lbs 10
04 Chipping Hammer Standard size 10
05 Wire brush Standard size 10
06 Anvil Standard size 01
07 Hand Gloves Standard size 05
08 Flat tongs Standard size 10
09 Steel scales 0-300mm 10
10 Flat file 14” rough bastard file 10
11 Oxygen cylinder Standard capacity 01
12 Acetylene cylinder Standard capacity 01
13 C02 Gas Cylinder Standard capacity 01
14 Gas welding torch Standard size 05
15 Spark lighter Standard size 05
16 Gas welding goggles Standard size 10
17 Gas cutting torch Standard size 02
18 Try square 6” 10
Carpentry shop
01 Carpenter Benchvice Standard size 20
02 G or C clamp 6’’ 20
03 Marking gauge Standard size 20
04 Try square 19mmx4″ 20
05 Wooden mallet Standard size 20
06 Firmer chisel 2″ 20
07 Firmer chisel 3/4″ 20
08 Mortise chisel 1/2″ 20
09 Metal jack plane 9″ 20
10 Beveled square 6″ 20
11 Hand saw or cross cut saw Standard size 20
12 Steel scale 12″ 20

Department of Technical Education, Government of Karnataka 16

 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION

Program ME & Allied Programs Semester I

Computer Aided Engineering
Course Name Type of Course Integrated
Drawing (CAED)
Course Code 25ME01I Contact Hours 7 Hrs/Week= 91Hrs

Teaching Scheme L: T:P [Link] Credits 5

CIE Marks 50 SEE Marks 50 (Practice)

1. Rationale: Engineering Drawing is universal & effective language of engineers that

strengthens the technological structure. It helps in communicating design ideas and technical
information to engineers and other professionals throughout the design process. The
objective of Engineering drawing & CAD is to introduce the students, the techniques of
drawing, visualize and represent 3D objects in 2D & create solid model.

2. Course Outcomes: At the end of the Course, the student will be able to:

CO-01 Use drawing instruments and dimension the drawing as per dimension standards.

CO-02 Draw the principal views of points, lines, planes and solids.

CO-03 Convert Orthographic views of a given drawing to pictorial Drawing.

CO-04 Create Solid model of the pictorial Drawing in CAD.

3. Course Content
*Note: Practice of Drawings should be done in Drawing Sheet (A2)only, Except
Orthographic drawings

WEEK CO PO Lecture Practical (CAD)

(3 Hours per Week) (4 Hours per Week)
Fundamentals of Engineering Practice different types of Lines
Drawing: using drawing instruments.
1, 4& Introduction to Engineering Drawing - Conventional representation of
1 1
7 Need for Engineering Drawing, Materials.
Instruments Used in Engineering
Drawing

Department of Technical Education, Government of Karnataka 17

 Layout of Drawing sheet, Title Block,
Types of Lines and its Applications.
Practice Dimensioning common
Dimensioning: features:
Introduction to dimensioning, Need Line, Radius, Diameter, Arc,
for dimensioning &Eelements of Chord, Angles, Sphere , Chamfer,
dimensioning. Hole, through hole, Counter bore
& Counter Sink.
Concept of Scale: Representative A. Practice Problems on Scaling
fraction (RF), Full scale, reduced scale B. Practice Problem on- Aligned
& enlarged scale. Conversion of Linear and Uni-direction system of
measurements of an object in mm, cm dimensioning.*
& Meter System of dimensioning:
Aligned system &Uni-direction
system.
Methods of Dimensioning
1,4 & [Link] Dimensioning
2 1
7
2. Parallel Dimensioning
3. Combined Dimensioning
4. Progressive Dimensioning
Practice Problems on Practice Problems on
A) Chain Dimensioning Dimensioning.*
B) Parallel Dimensioning
C) Combined Dimensioning
D) Progressive Dimensioning
Projection of Points: Practice Problems on projection
Planes of Projections and Views – of points.*
Principal planes & Views.
1,4 & First angle & Third angle projection
3 2
7 with symbolic representation
Problems on projection of points.
Practice Problems on projection of Practice Problems on projection
points of points.*
Projection of Lines (Only First angle Practice Problems on Projection
projection) for following conditions of Lines.*
 Line parallel to both HP & VP
 Line parallel to HP & Perpendicular
to VP
1,4 &
4 2  Line parallel to VP & Perpendicular
7
to HP.
 Line inclined to HP & Parallel to VP
Practice Problems on Projection
 Line inclined to VP & Parallel to HP.
of Lines.*

Department of Technical Education, Government of Karnataka 18

 Projection of Planes: Practice Problems on Projection
Problems on projection of Planes of Planes.*
(Triangular lamina & Square lamina)
With conditions:
1. Base edge resting on HP
2. Corner resting on HP
3. Inclination only to HP
1,4 & Problems on projection of Planes
5 2
7 (Pentagonal lamina & Hexagonal
lamina) with conditions:
1. Base edge resting on HP
2. Corner resting on HP
3. Inclination only to HP
Problems on projection of Planes Practice Problems on Projection
(Circular lamina only)with conditions: of Planes.*
Inclination only to HP.
Projection of Solids: Practice Problems on Projection
Problems on projections of Solids of Solids.*
(Triangular prism & Triangular
pyramid)with conditions:
1. Base edge resting on HP
2. Corner resting on HP
3. Base Inclination only to HP.
1,4& Problems on projections of Solids
6 2 (Square prism & Square pyramid)with
7
conditions:
1. Base edge resting on HP
2. Corner resting on HP
3. Base Inclination only to HP
Problems on projections of Cone with Practice Problems on Projection
conditions: of Solids.*
1. Base Inclination only to HP
Problems on projections of Solids Practice Problems on Projection
(Pentagonal prism & Pentagonal of Solids.*
pyramid)with conditions:
1. Base edge resting on HP
2. Corner resting on HP
1,4 & 3. Base Inclination only to HP.
7 2
7
Problems on projections of Solids
(Hexagonal prism & Hexagonal
pyramid)with conditions:
1. Base edge resting on HP
2. Corner resting on HP
Department of Technical Education, Government of Karnataka 19
 3. Base Inclination only to HP.
Problems on projections of Cylinder Practice Problems on Projection
with conditions: of Solids.*
1. Base Inclination only to HP
Orthographic Projections & Solid Familiarization of CAD window
Modeling: Commands like New file, saving
Draw Orthographic Views for Pictorial the file, Opening an existing
drawings. drawing file, Undo, Redo, move
commands, Menu bar, Tool bar,
Task bar &Ribbon bar.
Practice CAD commands like arc,
1,4 & circle, square, rectangle, chamfer,
8 3,4
7
Trim, inclined lines, Extend,
Extendto Next, Shell,
Fillet, Group, Array and Mirror
commands
Create Solid model for Pictorial
drawings in CAD & Extract
Views.*
Draw Orthographic Views for Pictorial Create Solid model for Pictorial
drawings. drawings in CAD & Extract
1,4 & Views.*
9 3,4
7 Draw Orthographic Views for Pictorial Create Solid model for Pictorial
drawings. drawings in CAD & Extract
Views.*
Draw Orthographic Views for Pictorial Create Solid model for Pictorial
1,4 &
10 3,4 drawings drawings in CAD & Extract
7
Views.*
Draw Orthographic Views for Pictorial Create Solid model for Pictorial
1,4 & drawings. drawings in CAD & Extract
11 3,4 Sectional Views with an arbitrary
7
Sectional Plane.*
Draw Orthographic Views for Pictorial Create Solid model for Pictorial
1,4 & drawings. drawings in CAD & Extract
12 3,4 Sectional Views with an arbitrary
7
Sectional Plane.*
Draw Orthographic Views for Pictorial Create Solid model for Pictorial
1,4 & drawings. drawings in CAD &Extract
13 3,4 Sectional Views with an arbitrary
7
Sectional Plane.*

Note - * Refer annexure for Practice Questions & portfolio evaluation

Department of Technical Education, Government of Karnataka 20

4. References:
Sl.
Author Title of Book Publication/Year
No.
01 Basant Agrawal/C N Agrawal Engineering Drawing 3rd Edition,
McGraw-Hill, 2019
02 K Venkata Reddy Textbook of Engineering Drawing 2nd Edition,
B S Publication
03 Venugopal K Engineering Drawing and Graphics 2009
with Auto CAD
04 N D Bhatt Engineering Drawing Charotar
Publication
05 Imtiaz Hashmi Fundamentals of Engineering Drawing Lambert Academic
Publishing,2010
06 M B Shah Engineering Drawing Pearson Education
India, 2013
07 Frederick E Giesecke and Ivan L Technical Drawing with Engineering Pearson Education
Hill Graphics Limited, 2013
08 K R Gopala Krishna Engineering Graphics Subhash
Publications
09 R K Dhawan Text book of Engineering Drawing S Chand
Publications
10 Maurice Arthur Parker Engineering Drawing with Worked Stanley Thornes
Examples, Volume 1 Publications

5. CIE Assessment Methodologies

*Note: Drawings should be practiced in Drawing Sheet (A2) only, Except Orthographic
drawings which shall be practiced in A4 sheet.

[Link] Duration Max

CIE Assessment Test Week
. (minutes) Marks

1. CIE-1 Theory Test 4 90 50

2. CIE-2 Practice Test 7 180 50 Average of all

CIE=50 Marks
3 CIE-3 Theory Test 10 90 50

4. CIE-4 Practice Test 13 180 50

CIE-5 Portfolio evaluation of all

5 the Drawing sheets and 1-13 50
activities through Rubrics

Department of Technical Education, Government of Karnataka 21

 Total 50 Marks
6. SEE – Practice Assessment Methodologies
7.
Sl. Duration Max. Min. Marks
SEE – Practice Assessment
No (minutes) Marks to Pass

1. Semester End Examination-Practice 180 50 20

8. CIE-1 Theory Test Model Question Paper

Program Mechanical Engineering Semester - I

Course Name Computer Aided Engineering Drawing. (CAED) Test I

Course Code 25ME01I Duration 90min Marks 50

Name of the Course Coordinator:
Note: Answer any one full question from each section. Each full question carries equal marks.
Q. Cognitive Course
Questions Marks
No Level Outcome
Section-1
1 a) Draw layout of drawing sheet & List different sizes of Drawing
sheet. Apply 1
b) Dimension the given sketch using aligned system with chain
method.

2 a) Draw Title block

Apply 1 10+15=25
b) Dimension the given sketch using unidirectional system with
parallel method.

Section-2
3 a) DrawthreeprincipalviewsofapointP,30mm below HP, 50mm
behind VP & 40mm from Left Profile Plane.
b) Draw the three principal views of a line 40 mm long when it is
placed parallel to VP and perpendicular to HP. The line is 10+15=25
L3 2
30mm above HP, 40mm in front of VP and 30mm from right
Profile plane.

Department of Technical Education, Government of Karnataka 22

 4 a) DrawthreeprincipalviewsofapointP,30mmAbove HP, 50mm
behind VP &40mm from Left Profile Plane

b) Draw the three principal views of a line40mm long which it is

inclined at 30°to VP and parallel to HP. The line is 30mm L3 2
above HP, 40mm in front of VP and 30mm from right profile
plane.

NotefortheCoursecoordinator:Eachquestionmayhaveone,[Link]
h section carry the same weightage of marks, cognitive level and course outcomes.

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

9. CIE-2 Practice Test model question paper

Program Mechanical Engineering Semester I

Course
Computer Aided Engineering Drawing. (CAED) Test II/IV
Name
Course Code 25ME01I Duration 180 min Marks 50
Name of the Course Coordinator:
Questions CO Marks
1. Draw the three principal views of a line 40 mm long when it is placed parallel
15
to both HP & VP. The line is 30 mm above HP,40 mm in front of VP and 2
30mmfromright Profile plane.
2. A triangular lamina of base edge 40mm rests with one its base edge on HP so
15
that the surface of the lamina is inclined at 30° to HP. Draw the projections of 2
the lamina.
3. A square Prism of base edge 40mm and height 60mm rests with one its base
20
edge on HP so that the axis of the prism is inclined at 30° to HP. Draw the 2
projections of the prism.
Scheme of assessment Q1 Scheme of assessment Q2 Scheme of assessment Q3
Front View = 5 Marks Initial position= 5 Marks In Initial Position:
Top View = 5 Marks In Inclined Position: Front View=5 Marks
Side View = 5 Marks Front View=5 Marks Top view= 5 Marks
Top view= 5 Marks In Inclined Position:
Front View=5 Marks
Top view= 5 Marks
Total Marks 50

Signature of the Course Coordinator Signature of the HOD

9. Suggestive Activities for Tutorials:

 The students shall do minimum of one suggested activities

 List is an Example and not inclusive of all possible activities of the course.
 Student and Faculty are encouraged to choose activities that are relevant to the topic.

Department of Technical Education, Government of Karnataka 23

 [Link]. Suggestive Activities for Tutorials

01 Prepare Nut and Bolt by 3D Printing

02 Prepare V block/ Patterns by 3D Printing

03 Prepare solid models of Inter-disciplinary components by 3D Printing

10. Rubrics for Assessment of Graded Exercises (Qualitative Assessment)

Need
Unsatisfactory Satisfactory Good Excellent

Students
Sl. Improvement

Score
Dimension
No.
(0-10) (11-20) (21-30) (31-40) (41-50)
1 Technical Significant Multiple Some errors Minor errors All details are
Accuracy errors make inaccuracies affecting in accurate
the drawing understanding interpretation 40
unusable. but or calculations
correctable.
2 Line Quality Lines are Lines are Inconsistent Clear lines Clean and
messy and uneven line quality with minor consistent 40
confusing. inconsistencies lines
.
3 Dimension Dimensions Many errors; Some Mostly Dimensions
are missing or hard to dimension accurate; are precise,
incorrect. interpret errors minor issues clear, and
affecting correctly 45
interpretation. positioned,
following
standards.
4 Presentation Very untidy; Messy;Present Somewhat Generally neat Extremely neat
& Neatness Very poor ation hinders neat;Some with minimal and organized;
presentation clarity layout issues flaws; minor all details easy 40
improvement to read
in Presentation
5 Adherence to Does not Limited Lacks Minor Aadheres to
Standards follow any adherence to consistency. deviations relevant
drawing standards from drawing 35
standards. standards. standards (ISO,
ANSI, etc.).
Average Marks = (40+40+45+40+35)/5 = 40/50
Note: Dimension and Descriptor shall be defined by the respective course coordinator as per the activities

Department of Technical Education, Government of Karnataka 24

11. SEE- Model Practice Question Paper

Program Mechanical Engineering Semester I

Computer Aided Engineering Duration 180 min
Course Name Drawing Course Code: 25ME01I
Maximum Marks 50
Questions CO Marks
1. A pentagonal Prism of base edge 40mm and height 60mm rests with one its
corner on HP so that the base of the prism is inclined at 30° to HP. Draw the 2 20
projections of the prism. (ANSWER SHEET)
2. Draw Orthographic views for the given pictorial Drawing (ANSWER SHEET) &
3,4 30
create solid model (CAD) for the same and Extract Views.
SchemeofassessmentforQ1 SchemeofassessmentforQ2
1. Drawing projections of a Solid 1. Drawing orthographic Views in
-15 Marks answer sheet-15 Marks
2. Adopting Dimension& Drawing 2. Creating solid model in CAD & print out -
convention (types of lines) -5Marks 10Marks
3. Extracting Views- 5 Marks
Total Marks 50

1) Signature of the Examiner 2) Signature of the Examiner

12. Equipment/software list with Specification for a batch of 30 students

[Link]. Particulars Specification Quantity

01 Drawing tables As per IS 30
02 CAD software - 30users
03 Computers Latest configuration 30

Department of Technical Education, Government of Karnataka 25

 *Annexure
Students shall practice these or similar questions for portfolio evaluation
1. Fundamentals of Engineering Drawing

Drawing Sheet No. 1 – (Student has to submit Minimum one standard size drawing sheets
(A2) in this unit for portfolio evaluation).
 DrawFig.1&Fig.2as per the drawing and identify types of lines.

Fig.1 Fig.2
2. Dimensioning
Drawing Sheet No.2 & 3 - (Student has to submit Minimum two standard size drawing
sheets (A2) in this unit for portfolio evaluation)

DrawFig.3to1:1scale,1:2 scale & 2:1scale.

Fig.3
 Copy Fig. 3 to 1:1 scale and dimension it using both Aligned system & Uni-directional system.
 CopyFig.4to2:1ScaleanddimensionitusingAlignedsystemwithChaindimensioning.

Department of Technical Education, Government of Karnataka 26

  Fig.4

 Copy Fig. 5 to 1:1 Scale and dimension it using Unidirectional system with Parallel dimensioning

 Fig.5
 Copy Fig. 6 to 1:1 scale and dimension it using unidirectional system with Combined dimensioning
method

 Fig.6
 Copy Fig. 7 to 1:1 scale and dimension it using Aligned system with Progressive dimensioning
method

Fig.7
 Copy Fig. 8 to 1:1 scale and dimension it using Aligned system with chain dimensioning method

 Fig.8

Department of Technical Education, Government of Karnataka 27

 2. Projection of Points

Drawing Sheet No.4- (Student has to submit Minimum one standard size drawing sheet (A2) in
this unit for portfolio evaluation).

Q1. Draw three principal views of a point P, 30mm Above HP, 50mm in front of VP&40mm from Left
Profile Plane.

Q2. Draw three principal views of a point P, 30mm Above HP, 50mm behind VP & 40mm from Left
Profile Plane.

Q3. Draw three principal views of a point P, 30mm Below HP, 50mm behind VP & 40mm from Left
Profile Plane.

Q4. Draw three principal views of a point P, 30mm Below HP, 50mm in front VP & 40mm from Left
Profile Plane.

3. Projection of Lines
Drawing Sheet No.5- (Student has to submit Minimum one standard size drawing sheet in this unit
for portfolio evaluation).

Q1. Draw the three principal views of a line 40 mm long when it is placed parallel to both HP & VP. The
line is 30 mm above HP, 40 mm in front of VP and 30mm from right Profile plane.

Q2. Draw the three principal views of a line 40 mm long when it is placed parallel to HP and
perpendicular to VP. The line is 30mm above HP, 40mm in front of VP and 30mm from right Profile
plane.

Q3. Draw the three principal views of a line 40 mm long when it is placed parallel to VP and
perpendicular to HP. The line is 30mm above HP, 40mm in front of VP and 30mm from right Profile
plane.

Q4. Draw the three principal views of a line 40mm long which it is inclined at 30° to HP and parallel to
VP. The line is 30mm above HP,40mm in front of VP and 30mm from right profile plane.

Q5. Draw the three principal views of a line 40mm long which it is inclined at 30° to VP and parallel to
HP. The line is 30mm above HP,40mm in front of VP and 30mm from right profile plane.

4. Projections of Planes
Drawing Sheet No.6 - (Student has to submit Minimum one standard size drawing sheet (A2) in
this unit for portfolio evaluation).

Q1. A triangular lamina of base edge 40mm rests with one its base edge on HP so that the surface of the
lamina is inclined at 30° to HP. Draw the projections of the lamina.

Q2. A triangular lamina of base edge 40mm rests with one its Corner on HP so that the surface of the
lamina is inclined at 30° to HP. Draw the projections of the lamina.

Q3. A square lamina of base edge 40mm rests with one its base edge on HP so that the surface of the
lamina is inclined at 30° to HP. Draw the projections of the lamina.
Department of Technical Education, Government of Karnataka 28
 Q4. A square lamina of base edge 40mm rests with one its corner on HP so that the surface of the lamina
is inclined at 30° to HP. Draw the projections of the lamina.

Q5. A pentagonal lamina of base edge 40mm rests with one its base edge on HP so that the surface of the
lamina is inclined at 30° to HP. Draw the projections of the lamina.

Q6. A pentagonal lamina of base edge 40mm rests with one its corner on HP so that the surface of the
lamina is inclined at 30° to HP. Draw the projections of the lamina.

Q7. A hexagonal lamina of base edge 40mm rests with one its base edge on HP so that the surface of the
lamina is inclined at 30° to HP. Draw the projections of the lamina.

Q8. A hexagonal lamina of base edge 40mm rests with one its corner on HP so that the surface of the
lamina is inclined at 30° to HP. Draw the projections of the lamina.

Q9. A circular lamina of 30mm diameter rests on HP such that the surface of the lamina is inclined at 30°
to HP. Draw the projections of the lamina.

5. Projections of Solids
Drawing Sheet No.7- (Student has to submit Minimum one standard size drawing sheet (A2) in
this unit for portfolio evaluation).
Q1. A triangular Prism of base edge40mm and height 60mm rests with one its base edge on HP so that
the base of the prism is inclined at 30° to HP. Draw the projections of the prism.

Q2. A square Prism of base edge 40mm and height 60mm rests with one its base edge on HP so that the
axis of the prism is inclined at 30° to HP. Draw the projections of the prism.

Q3. A pentagonal Prism of base edge 40mm and height 60mm rests with one its corner on HP so that
the base of the prism is inclined at 30° to HP. Draw the projections of the prism.

Q4. A hexagonal Prism of base edge 40mm and height 60mm rests with one its corner on HP so that the
base of the prism is inclined at 30° to HP. Draw the projections of the prism.

Q5. Atriangularpyramidofbaseedge40mmandheight60mmisrestingwithoneofitscorneron HP so that

axis of the pyramid is inclined at 30°to HP. Draw the projections of the pyramid.

Q6. Asquarepyramidofbaseedge40mmandheight60mmisrestingwithoneofitscorneronHP so that base of

the pyramid is inclined at 30°to HP. Draw the projections of the pyramid.

Q7. A pentagonal pyramid of base edge 40mm and height 60mm is resting with one of its base edge on
HP so that base of the pyramid is inclined at30°[Link] the pyramid.

Q8. Ahexagonalpyramidofbaseedge40mmandheight60mmisrestingwithoneofitsbaseedge on HP so that

base of the pyramid is inclined at30°[Link] the pyramid.

Q9. A cylinder of 40mm diameter and axis height 65mm rests with its base on HP so that the base
diameter inclined at 45° to the HP Draw the projections.

Q10. A cone of 40mm diameter and axis height 65mm is resting with its base on HP. Draw the
projections if base diameter is inclined at 45° to HP.
Department of Technical Education, Government of Karnataka 29
6. Pictorial Drawings.
Drawing Sheet No.8,9& 10 - (Student has to submit Minimum two standard size drawing
sheets(A2) in this unit for portfolio evaluation).

Q1. Draw the three principal views of the given [Link] the three principal views of the given
component. & Create Solid Model. component. & Create Solid Model.

3. Draw the three principal views of the given 4. Draw the three principal views of the given
component. & Create Solid Model. component. & Create Solid Model.

Department of Technical Education, Government of Karnataka 30

 Q5. Draw the three principal views of the given Q6 Draw the three principal views of the given
component. & Create Solid Model. component. & Create Solid Model.

7. Draw the three principal views of the given 8 Draw the three principal views of the given
component. & Create Solid Model. component. & Create Solid Model.

Department of Technical Education, Government of Karnataka 31

 Government Of Karnataka
DEPARTMENTOFTECHNICALEDUCATION
Curriculum Structure
II Semester Scheme of Studies – Mechanical Engineering

CIE Theory SEE Practice SEE

Hours/week
Department

Hours per week

Total Contact
Marks Marks Marks
Teaching

Credits
Sl. Total
Course Code Course Name
No. Marks
L T P Max Min Max Min Max Min

Integrated Courses

1 SC 25SC21I Engineering Mathematics-II 4 0 4 8 6 50 20 50 20 - - 100

2 CS 25CS01I IT Skills 3 0 4 7 5 50 20 - - 50 20 100

Fundamentals of Electrical &

3 EE 25EE01I 3 0 4 7 5 50 20 - - 50 20 100
Electronics Engineering
Mechanical Engineering
4 ME 25ME21I 4 0 4 8 6 50 20 50 20 - - 100
Practices-II
Audit Course
5 ME 25ME22T Indian Constitution 2 0 0 2 2 50 20 - - - - 50

Personality Students are expected to engage in any one of these activities from 1st semester to 6th semester
6 NCC/NSS/YOGA/SPORTS…
Development (No Credits)
-
Total 16 0 16 32 24 250 - 100 100 - 450
 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION
Program Mechanical Engineering Semester II
Mechanical Engineering
Course Name Type of Course Integrated
Practices-II
Course Code 25ME21I Contact Hours 104 hrs/Sem

Teaching Scheme L: T:P :: [Link] Credits 6

CIE Marks 50 SEE Marks 50 (Theory)

1. Rationale:
Material Science and Surface treatment are the fundamental concepts that equips diploma
students with knowledge of various materials, their properties, applications and surface
modification techniques. Understanding these concepts is crucial for students pursuing careers in
engineering, manufacturing and construction. Diploma Engineers are responsible for supervising
production processes to achieve production targets and for optimal utilization of resources. For
this purpose, knowledge about various manufacturing processes is essential.

Understanding the basics of Metal forming and Machine tool techniques are essential for
mechanical engineers that equip students with knowledge of various metal forming and
machining processes, tool design, and manufacturing methods. This requires training the students
with a focus on Casting and Sheet metal works, operations provide essential skills, knowledge,
and experience about the various manufacturing processes. Hence this integrated course is
introduced to provide strong foundation in practical skills, safety awareness, and problem-solving
abilities essential for success in mechanical engineering and related fields.

2. Course Outcomes: At the end of the Course, the student will be able to:

Identify the appropriate heat treatment & surface treatment processes for specified
CO-01 applications.
CO-02 Prepare the casting by using suitable patterns and molds for the given applications

CO-03 Select appropriate metal forming process for the specified applications

CO-04 Develop the sheet metal work for the given applications.

CO-05 Perform drilling and Grinding operations.

Department of Technical Education, Government of Karnataka 33

3. Details of Course Content

WEE
CO PO Theory Practice
K
Crystal structure
 Types of crystal structures –
 Types of Microscopes (SEM and TEMs)
Crystalline & Non-crystalline
-Use virtual lab web link [Link]
 Structure of metal –unit cell, [Link]/exp/sembasics/simulatio
BCC, FCC and HCP structures, [Link]
1 1 1,2 Mechanical Properties.
 Study the different crystal structures by
 Atomic Packing factor for BCC, using ball and stick or wire models.
FCC and HCP crystal structure
 Study the Iron Carbon diagram for phase
(no derivations)
changes.

Heat Treatment of Steel

 Objectives
 Types
a) Annealing (Ductility)
b) Normalizing (Machinability)
c) Hardening (Hardness)
d) Tempering (reduce hardness/
brittleness)
e) Case Hardening –
Carburizing, Nitriding, Heat Treatment
Cyaniding.  Safety precautions to be followed in
f) Surface hardening- Induction Heat Treatment shop
2 1 1,2,4 Hardening, Flame hardening
 Compare hardness of the work piece
*These concepts shall be thought by
before and after heat treatment process
using the following Examples
by using Hardness Testing Machine
Annealing: steel and steel alloys,
(BHN/RHN)
Normalizing: carbon steels and
alloy steels,
Tempering: steel in construction,
automotive, and machinery
applications, Carburizing: gears,
camshafts,
Nitriding: tools, dies, and engine
components *
Surface treatment Surface treatment
 Corrosion - Types, Methods of
reduction of corrosion
3 1 1,2,4  Surface coating processes -  Coat an iron key with copper and
Traditional methods - Painting, Copper sulphate using the electroplating
electroplating, Galvanizing,  Coat the brass plate with copper and
Spraying. Copper sulphate using the electroplating
Department of Technical Education, Government of Karnataka 34
  Advanced coating
technologies -Physical vapor
deposition, Chemical Vapor
deposition, Laser treatment.

* These concepts shall be thought by

using the following Examples
Electroplating: Zinc plating on steel,
Gold or silver plating on jewelry,
watches, and decorative items,
Nickel plating on machinery parts,
Gold plating on connectors and
circuit boards, Silver plating on
medical devices
Galvanizing: steel beams and
columns, steel poles for power lines,
brackets, bolts, and nuts, steel pipes
for plumbing,*
Advanced materials
 Biomaterials- Properties and
applications
 Smart Material - Piezoelectric
materials (Quartz, PZT and
PVDF), Shape memory alloys
(Nitinol, Ni–Mn–Ga)- Properties
and applications
 Energy Materials- Solar Display the different components made
Energy, Battery- Properties and up of advanced materials
applications  The students shall identify minimum 10
 Nano-materials-Classification, components and prepare the chart
properties and applications, showing the components diagram,
4 1 1,2,4
Carbon – based CNT and material type,properties and application
Graphene.

* These concepts shall be thought by

using teaching aids such as
Biomaterials - Bone cement,
Stitches, Stents, Bone plates,
Piezoelectric - Stoves, gas
burners. SMAs-shower heads, Stents.
Energy Materials – Silicon,
Lithium-Ion. Nano-materials – Face
Cream, Nano Filters, Baseball Bat*

Department of Technical Education, Government of Karnataka 35

 Additive Manufacturing
 Introduction to Additive
Manufacturing
 Explain the metal, polymer,
ceramic, and glass materials
used in Additive Manufacturing,
 Prepare a solid modeling of a simple
and its properties & limitations
component and convert into STL format.
5 2 1,2,4  Types of Additive
Manufacturing Technologies-  Prepare the component by Additive
Overview of FDM, SLA, SLS, and Manufacturing process
DMLS technologies
 Explain Step-by-step additive
manufacturing process
 Applications of Additive
Manufacturing

Casting process
 Types of casting process Foundry
 Pattern and Mould making:  Safety precautions to be followed in
 Patterns – Materials, types, Foundry shop
Pattern allowances  Prepare a pattern (carpentry or 3D
 Mould – Molding sand types, printed process)
properties and processes  check the pattern for dimensional
 Core making accuracy
6 2 1,2,4
 Defects in casting processes,  Inspect the pattern for defects
 Explain the different Types of  Prepare sand mold using pattern and
Modern Casting processes. core
 Pour metals (Al, Cu, Tin etc) into the
* This concept shall be thought by mold
using the teaching aids such as  After solidification remove the castings
Piston, Engine blocks, Wheels, Valve  Inspect the casting for defects.
bodies, etc*

Metal Forming Processes

 General classification of metal
forming processes
Bulk deformation processes
Forging
 Forging – Introduction,
classification, Applications  Safety precautions to be followed in
forging shop
 Rolling – Introduction,
7 3 1,2,4 Classification, Applications.  Demonstrate the Forging tools and
 Extrusion – Introduction, equipment ‘s
Classification, Applications  Convert Round rod into square rod
 Wire & Bar Drawing –
Introduction, Applications
* This concept shall be thought by
using the teaching aids such as
Forging – Tractor plows, combine

Department of Technical Education, Government of Karnataka 36

 harvesters, Crankshafts, connecting
rods, turbine discs, blades, Surgical
& Dentistry tools.
Extrusion – Bars, tubes, gear blanks,
aluminum cans, cylinders, frames,
doors, windows, Medical tubes,
bags.
Rolling – Structural steel I-Beams,
Angle stock, bar stock, rail track,
sheet metal. Wire and Bar drawing
- Electrical wires, cables, springs,
paper clips, musical instrument
strings*
Development and Preparation of surfaces
8 4 1,2,4  Development of Cone, Cylinder, Prism and Pyramid and Produce the model
 Development of Frustum of cone and Produce the model
Sheet metal work
 Introduction
 Standard gauges and
Specifications of sheet Sheet Metal work
metal  Prepare the development drawing of a
 Sheet metal operations- cylindrical box
Shearing, Bending,  Prepare the sheet metal cylindrical box and
Forming. Join end surfaces by means of Seam Joint and
9 4 1,4
 Applications of sheet metal soldering.
work  Prepare the development drawing of a
* This concept shall be Funnel
thought by using the teaching  Prepare the sheet metal Funnel and Join end
aids such as Automobile surfaces by means of Seam Joint and soldering.
components, Car body
building, Aircraft body
building*
Press Work
● Overview
● Types of Presses
● Press Components
● Press Operations
Press work
* This concept shall be thought  Safety precautions to be followed in press work
10 4 1,2,4 by using the teaching aids such  Perform the simple operation in Press tool by
as mechanical, hydraulic, using punch and Die
pneumatic presses and their
applications such as Washers,
brackets, and automotive body
components, frames, brackets,
and enclosures, automotive
components*

Department of Technical Education, Government of Karnataka 37

 Cutting tools and Abrasives:
● Cutting tool – classification
of Cutting tool
● Characteristics and Surface grinding operations
selection of tool materials. ● Safety precautions to be followed in surface
 Nomenclature of single grinding operation
point cutting tools ● Demonstration of surface grinding of machine
11 5 1,4  Nomenclature of milling parts
tools  Students shall perform surface grinding
 Abrasives used in grinding operation on the given job
wheels and its
designations
● Surface finishing processes
– Grinding, Polishing,
Coating.
Drilling Machine Drilling machine operations
● Introduction to drilling ● Safety precautions to be followed in drilling
Machine machine operation
● Classifications of drilling ● Demonstration of drilling machine parts
machine ● Demonstration of drilling, reaming and tapping
12 5 1,4
 Nomenclature of drilling, operation
reaming and tapping  Students shall perform drilling reaming and
cutting tools tapping operations on the given job
.  Measure the diameter of drilled hole by using
Go and No Go gauge
Lathe and Milling machines
● Safety precautions to be followed in machine operations
● Demonstration of Lathe parts
13 5 1,2,4
● Demonstration of Lathe operations
● Demonstration of milling machine parts
● Demonstration of milling machine operations

4. References:
Sl. No. Author Title of Books Publication/Year
Woodhead Publishing Limited,
1. J. W. Martin Materials for Engineering
3rd Edition, 2006
Material Science and Wiley Publications, 10th
2. William D. Callister Jr.
Engineering Edition, 2020
V K Manchanda, GBS Materials science and Khanna Publishers, 1st Edition,
3.
Narang, J S Narang Metallurgy 2021
Materials science and S.K. Kataria & Sons, 5th Edition
4. R.K. Rajput
Engineering 2016, Reprint 2024
Materials science and
5. V. Raghavan PHI, 6th Edition, 2016
Engineering
Introduction to Physical Tata McGraw-Hill Education,
6. Sidney H. Avner
Metallurgy 2nd Edition 2017
Department of Technical Education, Government of Karnataka 38
 Material Science and Pearson Education India, 1st
7. Parashivamurthy K I
Metallurgy Edition, 2012
Elements of Mechanical
8. K R Gopalakrishna 2019
Engineering
S. K. Hajra Choudhury, Elements of Workshop
Media Promoters & Publishers
9. A. K. Hajra Choudhury, Technology Vol-I
Private Limited - 2008
Nirijhar Roy Manufacturing Processes
Elements of Workshop
S. K. Hajra Choudhury, Media Promoters & Publishers
10. Technology Vol-II
Nirijhar Roy Private Limited - 2010
Machine Tools
11. R. B. Gupta Workshop Practice Stay Prakashan - 2024
Taylon Altan
12. Forming Fundamentals Arm International - 2012
Erman Tekkaya
13. Rahul Shivaji Autade Sheet Metal Engineering Nirali Prakashan - 2023

5. CIE Assessment Methodologies

Test Duration Max

[Link] CIE Assessment
Week (minutes) Marks
1. CIE-1 Theory Test 4 90 50
2. CIE-2 Practice Test 7 180 50 Average of all
3 CIE-3 Theory Test 10 90 50 CIE=50 Marks
4. CIE-4 Practice Test 13 180 50
CIE-5 Portfolio evaluation of all practices
5 1-13 50
and activities through Rubrics.
Total 50 Marks

6. SEE - Theory Assessment Methodologies

Sl. Duration Max Min marks

SEE – Theory Assessment
No (minutes) marks to pass
1. Semester End Examination-Theory 90 50 20

7. CIE Theory Test model question paper

Program Mechanical Engineering Semester- 2

Course Name Mechanical Engineering Practices - II Test I

Course Code 25ME21I Duration- 90 min Marks-50
Name of the Course Coordinator:
Note: Answer any one full question from each section. Each full question carries equal marks.
Q. No Questions CL CO Marks
Section - 1
a) Identify the mechanical properties found in BCC Crystal structure.
Suggest any 2 materials which exhibit BCC Crystal structure.
1 b) Appreciate the importance of Atomic Packing factors (APF) in crystal Apply CO1 5X5= 25
structures. Outline the APF of different crystal structures.
c) Identify the mechanical properties found in FCC Crystal structure.
Department of Technical Education, Government of Karnataka 39
 Outline any 2 materials which exhibit BCC Crystal structure.
d) Highlight the Characteristics of Crystalline and Non-Crystalline
structures with examples.
e) Identify the mechanical properties found in HCP Crystal structure.
Outline any 2 materials which exhibit BCC Crystal structure.
a) Suggest an appropriate heat treatment process to improve the wearand
fatigue properties of machine tool guide ways. Describe the process
indetail.
b) Substantiate why normalizing is more commonly used than annealing
after performing cold work on hardenable steels.
c) Identify the appropriate surface hardening process for the Stainless
2 Apply CO1 5X5 = 25
steels used in various industrial applications
d) Identify the heat treatment process suitable for a steel shaft used in a
high – speed turbine. Highlight the properties improved after heat
treatment.
e) Why is annealing crucial for copper components used in electrical
applications? Justify your answer.
Section - 2
a) Suggest the best coating technique for the parts used in marine
applications to prevent corrosion and enumerate the coating process.
b) Identify any 5 metals which corrode into its oxides/sulphides when
subjected to harsh corrosive environment.
c) Suggest the best surface coating technique to prevent corrosion in AC
3 Apply CO1 5X5 = 25
ducts used in multistoried buildings and enumerate the coating process.
d) Identify the best coating/surface treatment technique available to arrest
corrosion of nuts and bolts. Highlight the coating process in detail.
e) Identify the Advanced coating techniques for electronic and optical
applications. Justify your selection.
a) Suggest the advanced material used for the manufacturing of Stents.
Highlight its properties.
b) Identify the Properties required for the production of Energy materials
such as batteries.
c) Discuss how Nano filters can benefit water purification through
4 Apply CO1 5X5 = 25
filtration?
d) Which material is suitable for solar panels? Justify your answer.
e) Nano materials are used in Face cream applications. What are the
benefits of using it over traditional materials? Suggest a suitable nano
material.
Note for the Course coordinator: Each question may have two, three, four or five subdivisions. Optional
questions in each section carry the same weightage of marks, cognitive level and course outcomes.

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

Department of Technical Education, Government of Karnataka 40

8. CIE Practice Test model question paper

Program Mechanical Engineering Semester 2

Course Name Mechanical Engineering Practices - II Test II
Course Code 25ME21I Duration 180 min Marks 50
Name of the Course Coordinator:
Note: Answer any one full question from the following
Questions CO Marks

1. a. Explain the Safety precautions used in Foundry shop.

b. Prepare the mould using the pattern as per the diagram.

2. a. Outline the steps involved in Casting process

b. Prepare the mould using the pattern as per the diagram.

10+15+25 = 50
CO2
Marks

Q . No – 1 (b)

Department of Technical Education, Government of Karnataka 41

 Q. No – 2 (b)

Scheme of Assessment
Q No.1& 2
a. Identify safety outfits, usage of appropriate safety method 10 Marks
b. Listing of tools & operations required for performing job 10 Marks
Preparation of Mould 15 Marks 50 Marks
Operation performed (Mould cavity) 10 Marks
Finishing and Dimensional accuracy of the Mould 05 Marks
Total 50 Marks

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

Department of Technical Education, Government of Karnataka 42

9. Suggestive Activities for Tutorials:
 The students shall do minimum of one suggested activities
 List is an Example and not inclusive of all possible activities of the course.
 Student and Faculty are encouraged to choose activities that are relevant to the topic.

[Link]. Suggestive Activities for Tutorials

01 Prepare simple aluminum castings such as washers, Nuts and bolts used in automobiles
02 Prepare a bracket by using sheet metal operations.
03 Coat Zinc into Mild steel surface by using surface treatment technique.

10. Rubrics for Assessment of Graded Exercise (Qualitative Assessment)

Need
Sl. Unsatisfactory Satisfactory Good Excellent Student
Dimension Improvement
No. (0-5) (6-10) (11-15) (16-20) (20-25)
Score
Lacks several Adequately Mostly
Fully prepared
Not prepared important prepared but prepared
1 Preparation
at all materials or missing key with minor
with all necessary 20
materials and tools
tools items omissions
Some Minor Test or task
Major errors inconsistencie errors in performed
Execution/Impl Task not
2 ementation executed
affecting results s or execution, flawlessly with 20
or functionality inaccuracies but overall precision and
present effective accuracy
Poor quality, Acceptable
Good quality High-quality
No quality major flaws quality with
3 Quality of Work demonstrated impacting noticeable
with minor output, meets or 15
flaws exceeds standards
functionality defects
Mastery of tools
Good use of
No proper tool Weak use of Basic use of and techniques
Use of Tools/ tools, minor
4 use tools, significant tools, some demonstrated 20
Techniques issues with
demonstrated risks noted inefficiencies safely and
technique
effectively
Most All required
Major sections
Major sections Some sections sections are sections are
Practical are missing or
5 are not are included, complete included and 25
Record poorly
addressed. but lack detail. with minor thoroughly
addressed.
omissions. detailed.
Average Marks=(20+20+15+20+25)/5=20 20
Note: Dimension and Descriptor shall be defined by the respective course coordinator as per the activities

Department of Technical Education, Government of Karnataka 43

11. SEE–Model Theory Question Paper

Program Mechanical Engineering Semester-2

Course Name Mechanical Engineering Practices - II Marks-50
Course Code 25ME21I Duration - 90 Min
Note: Answer any one full question from each section. Each full question carries equal marks.
Q
Questions CL CO Marks
No
Section -1
c) When designing a component that requires high strength and
ductility, how would you select between materials with BCC and FCC
5+5=
1 structures? Provide reasoning based on their mechanical properties. Apply CO1
10Marks
d) What are the limitations of flame hardening compared to induction
hardening? In what scenarios would flame hardening be preferred?
c) How do advanced coating technologies like PVD and CVD improve
performance compared to traditional methods? Provide examples of
5+5=
2 industries where these methods are preferred Apply CO1
10Marks
d) How would you choose a biomaterial for a specific orthopedic
implant? Discuss the key properties that must be considered.
Section -2
c) Given the need to produce a complex-shaped automotive part, how
would you determine which casting process to use (e.g., sand casting vs.
die casting)? What factors would you consider? 5+5=
3 Apply CO2
d) Provide an example of a specific industry where casting is critical. 10Marks
Discuss why casting is preferred over other manufacturing processes for
certain components in that industry.
c) Identify common defects in casting and suggest strategies to prevent
them.
5+5=
4 d) How are modern casting techniques like 3D printing influencing Apply CO2
10Marks
traditional mold making and casting processes? Provide examples of
industries benefiting from these advancements.
Section -3
a) Provide an example of a product that is commonly produced by
extrusion. Discuss the advantages of using extrusion for this product
compared to alternative manufacturing processes. 5+5=
5 b) How would you determine the best material for a specific forging Apply CO3 10Marks
application in the automotive industry? What properties would you
prioritize?
c) Discuss how rolling affects the mechanical properties of metals.
What changes occur in grain structure and hardness as a result of the
rolling process?
5+5=
6 d) Provide an example of a specific application where wire drawing is Apply CO3
10Marks
critical. Discuss why drawing is preferred over other manufacturing
processes for this application.

Section -4
c) How would you choose between aluminum and steel for a specific
sheet metal application in the automotive industry? What factors, such
as weight, cost, and strength, would influence your decision? 5+5=
7 d) How do you select the appropriate sheet metal material for a specific Apply CO3 10Marks
application in the aerospace industry? What mechanical properties are
critical?

Department of Technical Education, Government of Karnataka 44

 c) Provide examples of specific industries that predominantly use each
type of press (mechanical, hydraulic, pneumatic). What unique
requirements do these industries have that influence their choice of 5+5=
8 Apply CO3
press type? 10Marks
d) To manufacture frames, brackets, and enclosures, which press
operation/s, is/are recommended? Justify your answer.
Section -5
c) For a job requiring the machining of a Gears, which machine tool would
you recommend? Discuss the basic operations performed by the
machine. 5+5=
9 d) For a job requiring the machining of a keyway, would you recommend Apply CO5 10Marks
using a shaper or a milling machine? Justify your choice based on the
specific operations performed by each machine.
a) When would you choose a single-point cutting tool over a multi-point
cutting tool in a machining operation? Provide a specific example.
5+5=
10 b) In a manufacturing process aiming for a highly reflective finish on Apply CO5
10Marks
stainless steel, what polishing techniques would you employ? Why are
these techniques chosen?

13. Equipment/softwarelistwithSpecificationforabatchof30students

[Link] Particulars Specification Qty

.
01 Standard specimens Hardness testing specimens (ASTM E18 for Rockwell) 05
02 Hardness Tester Rockwell hardness-scales A,B andC. 01

03 Hardness Tester Brinnel Hardness tester 01

04 Desktop Computers Latest Configurations 20

Any latest Authorized Computer Aided Drafting
05 CAD Software 20
Software
06 FDM 3D Printer Any PLA/ABS 3D printers 02
Foundry Shop
01 Moulding Box 300*300*100mm 20
02 Moulding Rammer Standard Size 20
03 Moulding Tool kit Standard Size 20
Electric furnace for melting
(Wax/Low melting point metal
04 Standard Size 04
with crucible and ladder for
pouring)
Portable grinder for cleaning
05 Standard Size 02
of casting
06 Sand Blaster Standard Size 04
07 Ball peenHammer ½ lb 05
08 Pattern MakingToolkit Standard size 10

Department of Technical Education, Government of Karnataka 45

09 Furnace Furnace 01
Sheet Metal Shop
Sheet shearing Standard size
01 04
Machine(Manual or M/c type)
02 Sniper for cutting sheet Standard size 20
03 Metal stake Standard size 10
04 Wooden mallet Standard size 20
05 Plastic Hammer Standard size 20
06 Bench vice for Bending of sheet Standard size 05
07 Brazing Gun Standard size 10
Press Work
01 Power press Power house 10 ton 01
02 Hand power press Hydraulic shop press with gauge 04
03 Progressive die Standard size 04
04 Bending die Standard size 04
05 Combination die 01
Standard size Set
Machine Shop
01 Drilling Machine Radial Drilling Machine 01
02 Surface Grinding Machine Surface Grinding Machine 01
03 Tool grinding machine Tool grinding machine 01
04 lathe Centre lathe 15
05 Milling Machine Milling Machine 01

Department of Technical Education, Government of Karnataka 46

 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION
Curriculum Structure
III Semester Scheme of Studies- Mechanical Engineering

CIE Theory SEE Practice SEE

Hours/week
Hours per week
Department

Total Contact
Marks Marks
Teaching

Marks

Credits
Course Code Course Name Total
Sl. Max Min Max Min Max Min
No. L T P Marks

Integrated Courses

1 ME 25ME31I Mechanics of Materials 4 0 4 8 6 50 20 50 20 - -

100

2 ME 25ME32I Thermal Engineering 4 0 4 8 6 50 20 50 20 - - 100

3 ME 25ME33I Fluid Power Engineering 3 0 4 7 5 50 20 - - 50 20

100

4 ME 25ME34I Programming Concepts in 3 0 4 7 5 50 20 - - 50 20

100
Mechanical Engineering
Audit Course
Kannada –I
5 KAN 25KA31T 2 0 0 2 2 50 20 - - -
- 50
(ಸಾಹಿತ್ಯ ಸಿಂಚನ-I/ಬಳಕೆ ಕನನಡ-I)
Total 16 0 16 32 24 250 - 100 - 100
- 450
 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION

Program Mechanical Engineering Semester III

Course Name Mechanics Of Materials Type of Course Integrated

Course Code 25ME31I Contact Hours 8Hr/Week = 104 Hrs

Teaching Scheme L: T:P [Link] Credits 6

CIE Marks 50 SEE Marks 50 (Theory)

4. Rationale:
Day by day engineering & technology experience tremendous growth. Design& analysis plays
important role in developing engineering & technology. Mechanics of Materials is a foundational
subject in engineering that focuses on the behavior of materials under different loading
conditions.
Force Analysis helps determine the internal and external forces acting on structures, which is
crucial for predicting how materials will behave under load. Stress and Strain concepts describe
material deformation. Stress quantifies internal forces, while strain measures the resulting
deformation. Understanding this relationship is vital for material selection and design to prevent
failure. Material testing provides critical data on a material's strength, ductility, and elasticity,
enabling engineers to make informed design decisions.
Shear Force Diagram (SFD) and Bending Moment Diagrams illustrate how internal shear forces
and bending moments vary along the length of structural elements, helping engineers design safe
and efficient beams and structures. Center of Gravity and Moment of Inertia concepts are crucial
for understanding how forces affect a structure’s stability (CG) and its resistance to bending or
rotation (Moment of Inertia), which are vital for efficient design.
Overall, these topics form the core of Mechanics of Materials, providing diploma engineers with
the tools to design and analyze structures that are both safe and effective under various loading
conditions.

5. Course Outcomes: At the end of the Course ,the student will be able to:

Determine the Resultant force, Stress, Strain, Elastic Constants for a given problem.
CO-01
Identify the properties of material by conducting Tensile, Compression, Bending , Shear
CO-02
Department of Technical Education, Government of Karnataka 48
 and Impact tests for a given specimen
Draw Shear Force Diagram (SFD) & Bending Moment Diagram (BMD) of beams under
CO-03 various load conditions and Solve Bending stress in beams subjected to External loads.
Calculate Centre of Gravity (C.G) & Moment of Inertia (M.I) for T, L, I and Channel
CO-04 sections.

CO-05 Validate the theoretical results with FEM software

6. Course Content

WEEK CO PO Theory Practice

Force Analysis -
 Introduction to Force, Characteristics
of a force, Effects of force & System of
forces.  Lami’s Theorem – Concept
and validate using
 Concept of resultant, Resolution of
1 1 1,3 apparatus.
forces & Composition of forces
 ASTM standards for tensile,
 Problems on Resolution of forces-
compression, shear and
Analytical Method
bending.
 Finding Resultant Force by Graphical
Method
Tensile & Compression
testing-
Stress and Strain -  Conduct Tensile test for
 Concept of Stress & strain, types of the given Specimen and
Stresses-Normal stress (Tensile Determine Stress, Strain,
stress & Compressive stress), shear Young’s Modulus, Yield Stress,
stress & Thermal stress. Maximum Stress, % increase
in Length and % decrease in
2 1,2 1,2,3,4  Types of Strain-Longitudinal strain &
Area
Lateral Strain, Poisons ratio.
 Conduct Compression
 Stress-strain Curve for Ductile &
test for the given Specimen
brittle materials.
and Determine Stress, Strain,
 Hooks Law, Elastic Constants, Factor Young’s Modulus, Yield Stress,
of safety. Maximum Stress, %
Reduction in Length and %
Increase in Area.
Bending & Shear testing -
 Conduct Bending test for
Problems on Stress and Strain - the given Specimen
1,2,3,  Simple problems to calculate  Conduct Shear test for
3 1,2
4 stress, strain, deformation and the given Specimen
Young’s Modulus. Impact Testing
 Conduct the Impact
Testing on a given

Department of Technical Education, Government of Karnataka 49

 materialTodetermine the
Impact strength for using
Charpy / Izod testing machine

Introduction to FEM
Problems on Elastic Constants - software

4 1,5 1,2,3,4  Problems on Elastic constants to  Practice on FEM Software

calculate Young’s Modulus, Bulk  Validate problems related to
Modulus & Rigidity Modulus. deformation and stress
using FEM Software.
Shear Force (SF) and Bending
Moment (BM) -
 Introduction of Beam, Shear force,
Bending moment & Types of
Beams. Problem Validation using
 Types of Loads acting on a beam FEM
5 3,5 1,2,3,4 &Concept of sagging and Hogging Validate problems related to
bending moment deformation and stress using
 Maximum bending moment, Point FEM Software.
of contra flexure & Sign
conventions for drawing Shear
Force Diagram (SFD) & Bending
Moment Diagram (BMD)
SF and BM Validation using
Problems on Shear Force and FEM
Bending Moment
 Problems on Shear Force Diagram
6 3,5 1,2,3,4 Validate Problems solved on
(SFD)&Bending Moment Diagram
(BMD) for a cantilever beam Shear Force Diagram
subjected to point load & Uniformly (SFD)&Bending Moment
Distributed load (UDL) Diagram (BMD) using FEM
Software
Problems on Shear Force and SF and BM Validation using
Bending Moment FEM
 Problems on Shear Force Diagram Validate Problems solved on
7 3,5 1,2,3,4 (SFD)&Bending Moment Diagram Shear Force Diagram
(BMD) for a Simply Supported (SFD)&Bending Moment
beam subjected to point load & Diagram (BMD) using FEM
Uniformly Distributed load (UDL) Software
Theory of Simple Bending:
Introduction to Simple bending, SF and BM Validation using
Assumptions made in theory of simple FEM
bending & concept Bending stress.
Validate Problems solved on
8 3,5 1,2,3,4 Bending Equation (Without Proof), Shear Force Diagram
Moment of Inertia for different (SFD)&Bending Moment
sections (rectangular, hollow Diagram (BMD) using FEM
rectangular, Circular & hollow circular Software.
sections), Modulus of section for
different sections(rectangular, hollow
Department of Technical Education, Government of Karnataka 50
 rectangular, Circular & hollow circular
sections).
Bending Moment for Different
Sections-
 Cantilever beam with point load at
free end. Bending problem Validation
 Cantilever beam with Uniformly using FEM
Distributed load (UDL) throughout
the length. Demonstrate the validation of
 Simply Supported beam with point Problems on Bending
load at centre. Equation using FEM Software.
 Simply Supported beam with
Uniformly Distributed load (UDL)
throughout the length.
Problems on Bending Equation
Bending problem Validation
 Cantilever beam with point load at using FEM
free end.
9 3,5 1,2,3,4 Validate Problems solved on
 Cantilever beam with Uniformly
Bending Equation using FEM
Distributed load (UDL) throughout
Software.
the length.

Problems on Bending Equation Bending problem Validation

 Simply Supported beam with point using FEM -
load acting at Centre.
10 3,5 1,2,3,4 Validate Problems solved on
 Simply Supported beam with
Uniformly Distributed load (UDL) Bending Equation using FEM
throughout the length. Software.

Centre of Gravity (C.G) and Moment

of Inertia (M.I) -
 Concept of Centre of Gravity (C.G) & C.G & M.I Problems
Moment of Inertia, Parallel & Validation using FEM -
Perpendicular Axis Theorem.
11 4,5 1,2,3,4  Centre of Gravity (C.G) of Standard Validate Problems solved on
Sections (Rectangle, Triangle, Centre of Gravity (C.G) &
Square, Circle, Semi-circle, Moment of Inertia (M.I) Using
Trapezium & Cone FEM Software.
 Problems on Centre of Gravity (C.G)
of T- Section and I- Section.
Problems on C.G & M.I C.G & M.I Problems
 Problems on Centre of Gravity (C.G) Validation using FEM -
of L- Section and Channel Section.
12 4,5 1,2,3,4  Moment of Inertia (M.I) of T-Section Validate Problems solved on
and L- Section about an XX & YY axis Centre of Gravity (C.G) &
passing through Centre of Gravity Moment of Inertia (M.I) Using
(C.G). FEM Software.

Department of Technical Education, Government of Karnataka 51

 C.G & M.I Problems
Problems on C.G & M.I
Validation using FEM -
 Moment of Inertia (M.I) of I - Validate Problems solved on
13 4,5 1,2,3,4 Section and Channel section about
Centre of Gravity (C.G)
an XX & YY axis passing through
&Moment of Inertia
Centre of Gravity (C.G).
(M.I)Using FEM Software.

7. References:
Sl. No. Author Title of Books Publication/Year
McGraw Hill Education,
1. S Timoshenko Engineering Mechanics
5th edition, 2013
CBS publisher, 2nd Edition,
2. M G James & S P Timoshenko Mechanics of Materials
2004
Vikas Publishing House,
3. S SBhavikatti Strength of Materials
4th edition, 2013
Dhanpat Rai Publishing
4. S Ramamrutham Strength of Materials Company (p) Ltd, 16th
edition,
5. MadhukarVable Mechanics of Materials Second Edition
Ferdinand P. Beer, E. Russell McGraw Hill Education,
6. Mechanics of Materials
Johnston, Jr, John T. Dewolf 6th edition, 2012
Introduction to Finite
Tirupathi R. Chandrupatla, Cambridge University
7. Elements
Ashok D. Belegundu Press, 5th Edition
in Engineering
Prentice Hall India
Text book of Finite Element
8. P Seshu Learning Private Limited,
Analysis
1st edition, 2003

9. [Link]

6. CIE Assessment Methodologies

Duration Max
[Link] CIE Assessment Test Week (minutes) marks
1. CIE-1 Theory Test 4 90 50
2. CIE-2 Practice Test 7 180 50 Average of all
3 CIE-3 Theory Test 10 90 50 CIE=50
4. CIE-4 Practice Test 13 180 50 Marks
CIE-5 Portfolio evaluation of
5. all practices and Activities 1-13 50
through Rubrics
Total 51 Marks

Department of Technical Education, Government of Karnataka 52

7. SEE - Theory Assessment Methodologies

Duration Min marks to

[Link] SEE – Theory Assessment Max marks
(minutes) pass
Semester End Examination-
1. 90 50 20
Theory

7. CIE Theory Test model question paper

Program Mechanical Engineering Semester - III

CourseName Mechanics Of materials Test I/III
CourseCode 25ME31I Duration 90 min Marks 50
Name of the Course Coordinator:
Note:[Link] marks.
Cognitive Course
[Link] Questions Marks
Level Outcome
Section - 1
a)The forces 20N, 30N, 40N, 50N & 60N are acting at one of the
angular point of a regular hexagon towards the other five
angular point taken in order. Find the magnitude and direction
of the resultant force. 10+15=
Apply 1
1 b) A metal bar 50×50mm is subjected to an axial compression 25
of 500kN. the reduction in length is 0.5mmover a gauge length
of 200mm and increase in thickness is 0.04mm. find values of
elastic constants.
a) The following forces act at a point
i) 20N inclined at 30° towards the north of east
ii) 25N towards north
iii) 30N inclined at 45° towards north west
Apply 10+15
iv) 35N inclined at 40° towards south of west 1
2 =25
Find the magnitude & direction of the resultant force.
b) A rod of 30mm Diameter is subjected to a pull of [Link]
measured extension on gauge length of 200mm is0.09mm.
change in diameter is 0.0039mm calculate Elastic constants

Section - 2

(a) Compare and contrast the stress-strain diagrams of the steel

and ceramic materials, explaining the differences in terms of
ductility and brittleness.
b) A rod of 30mm diameter is subjected to an axial Pull of 80kN.
The measured extension is 0.1 mm on a gauge length of
Apply 5+10+1
3 200mm and the change in diameter is 0.004mm. Calculate the 1
0=25
poison’s ratio and the values of young’s Modulus, bulk
modulus and Modulus of rigidity.
c) A steel bar 50mm wide, 12mm thick and 300mm long is
subjected to an axial pull of 100kN. find change in length,
width& thickness of the bar. take E = 200 kN/mm2,µ=0.32

Department of Technical Education, Government of Karnataka 53

 a)In designing a bridge with steel cables, the cables are
subjected to tensile forces due to the weight of the bridge and
vehicles. Steel has a Young’s Modulus of 200 GPa and Poisson’s
ratio of 0.3. How does the linear strain in the steel cables affect
the total length of the cables when they are under load? Discuss
how this deformation could impact the design of the bridge.
b) A steel rod 30mm x 12.5mm and 500mm long is subjectedto Apply 5+10+1
4 1
an axial pull of 75kN. Determine the changes in length, width 0=25
and thickness and volume of bar. If young’s modulus is
200kN/mm2, µ=0.32
c) The young’s modulus for a given material is 100kN/mm2and
its modulus of rigidity is 40kN/mm2. Determine its bulk
modulus and also its lateral contraction if the diameter is
50mm and length 2m and extension 2mm.
Note for the Course coordinator: Each question may have one, two or three subdivisions. Optional questions in
eachsectioncarrythesameweightageofmarks,cognitivelevelandcourseoutcomes.

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

8. CIE Practice Test model question paper

Program Mechanical Engineering Semester III

Course Name Mechanics Of Materials Test II/IV
Course Code 25ME31I Duration 180 min Marks 50
Name of the Course Coordinator:
Questions CO Marks
[Link] forces 20N, 30N, 40N, 50N & 60N are acting at one of the angular point of a
1
regular hexagon towards the other five angular point taken in order. Find the
magnitude of the resultant force by graphical method.

2. Conduct Tensile test for the given Specimen and Determine Stress, Strain, Young’s 10+40=
Modulus, Yield Stress, Maximum Stress, % increase in Length and % decrease in Area 50
OR
Conduct Compression test for the given Specimen and Determine Stress, Strain,
Young’s Modulus, Yield Stress, Maximum Stress, % Reduction in Length and %
2
Increase in Area.
Scheme of Evaluation
Q. No 1
a) Drawing Regular hexagon = 4 Marks
Finding Magnitude = 2 Marks, Finding Direction = 2 Marks, CO1 10
b) Writing Observation & Tabular Column=10 Marks
Conduction of an Experiment = 20Marks CO2
Calculation & result = 10 Marks 40
Total Marks 50

Signature of the Course Coordinator Signature of the HOD

Department of Technical Education, Government of Karnataka 54

 9. Suggestive Activities for Tutorials:

 The students shall do minimum of one suggested activities

 List is an Example and not inclusive of all possible activities of the course.
 Student and Faculty are encouraged to choose activities that are relevant to the topic.

[Link]. Suggestive Activities for Tutorials

01 Find Centre of Gravity (C.G) of flywheel.
Stress concentration analysis on a Plate with circular hole (Varying diameter) using FEM
02
Software.
Stress concentration analysis on a Plate with circular hole (Varying position) using FEM
03
Software

10. Rubrics for Assessment of Experiments (Qualitative Assessment)

Need
Unsatisfactory Satisfactory Good Excellent
Sl. Improvement Student
Dimension
No. Score
(0-5) (6-10) (11-15) (16-20) (20-25)

Lacks several Adequately Mostly Fully prepared

Not prepared important prepared but prepared with all necessary
1 Preparation 20
at all materials or missing key with minor materials and
tools items omissions tools
Some Test or task
Minor errors
Execution/ Major errors inconsistenci performed
Task not in execution,
2 Implementa affecting results es or flawlessly with 20
executed but overall
tion or functionality inaccuracies precision and
effective
present accuracy
Poor quality, Acceptable High-quality
Good quality
Quality of No quality major flaws quality with output, meets or
3 with minor 15
Work demonstrated impacting noticeable exceeds
flaws
functionality defects standards
Mastery of tools
Good use of
Use of No proper tool Weak use of tools, Basic use of and techniques
tools, minor
4 Tools/ use significant risks tools, some demonstrated 20
issues with
Techniques demonstrated noted inefficiencies safely and
technique
effectively
Most All required
Some
Practical Major sections Major sections sections are sections are
sections are
5 Record are not are missing or complete included and 25
included, but
submission addressed. poorly addressed. with minor thoroughly
lack detail.
omissions. detailed.
Average Marks=(20+20+15+20+25)/5=20 20
Note: Dimension and Descriptor shall be defined by the respective course coordinator as per the activities

Department of Technical Education, Government of Karnataka 55

 11. SEE–Model Theory Question Paper

Program Mechanical Engineering Semester III

Course Name Mechanics of Materials Marks 50
Course Code 25ME31I Duration 90 Min
Note: Answer any one full question from each section. Each full question carries equal marks.
Cognitive Course
Q No Questions Marks
Levels Outcomes
Section -1
a. Explain types of Strain.
CO1 5
b. State parallel Axis theorem & Perpendicular axis Apply
1 CO4 5
theorem
a. Differentiate ductile &Brittle materials with respect to
stress strain diagram. CO1 5
2 Apply
b. Locate Centre of Gravity for Triangle, Rectangle, Circle, CO4 5
Semi-circle & Trapezium with the help of plain figure
Section -2
A metal bar 50×50 mm is subjected to an axial compression
of 500KN. the reduction in length is 0.5mm over a gauge
3 Apply CO1 10
length of 200mm and increase in thickness is 0.04mm. find
values of elastic constants.
A rod of 30mm Diameter is subjected to a pull of [Link]
4 measured extension on gauge length of 200mm is 0.09mm. Apply CO1 10
change in diameter is 0.0039mm calculate Elastic constants.
Section -3
Draw Shear Force Diagram (SFD) & Bending Moment
Diagram (BMD) for a Simply supported beam of span 10m .
It carries point loads of 3kN,4kN& 5kN at a distance of
5 Apply CO2 10
2m,4m & 6m from Right support. It also carries Uniformly
Distributed load (UDL) of 2kN/m over length of 4m from
left support.
Draw Shear Force Diagram (SFD) & Bending Moment
Diagram (BMD) for a Simply supported beam of span 10m.
6 It also carries point load of 2kN & 3kN at distance of 2m & Apply CO2 10
6m from Right support. It also carries Uniformly
Distributed load (UDL) of 2kN/m in between point loads.
Section -4
A timber joist 150x350mm is simply supported over a span
7 of [Link] it is carrying a UDL of 15kN/m inclusive of its own Apply CO3 10
weight. Find maximum bending stress induced in the beam.
A Beam is simply supported & carries UDL of 30kN/m over
the entire span. The section of the beam is rectangular
8 having depth of 400mm. If maximum stress in the material Apply CO3 10
is 120N/mm2& Moment of inertia of the section is
[Link] the span of the beam
Section -5
Calculate M.I. of an Angle section 100 X 80 X 10 mm about an
9 Apply CO4 10
XX axis passing through the centroid.

Department of Technical Education, Government of Karnataka 56

 Calculate M.I. for a given
section about an YY axis
passing through the
centroid.
10 Apply CO4 10

11. Equipment/softwarelistwithSpecificationforabatchof30students

[Link]. Particulars Specification Quantity

01 FEM Software - 30 Users
02 Computer Latest Configuration 30
03 UTM 40 ton 01
04 Impact Testing machine 01

Department of Technical Education, Government of Karnataka 57

 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION

Program MECHANICAL ENGG Semester III

Course Name Thermal Engineering Type of Course Integrated

Course Code 25ME32I Contact Hours 104 Hrs/Sem

Teaching Scheme L: T:P: [Link] Credits 6

CIE Marks 50 SEE Marks 50 (Theory)

1. Rationale:

Thermal Engineering is a vital discipline that covers key concepts in thermodynamics, heat
transfer, and energy systems, providing a strong foundation for engineering students. The course
starts with basic thermodynamics and progressively advances to applications such as thermal power
plants and gas turbines. A thorough understanding of heat transfer mechanisms—conduction,
convection, and radiation—is essential for optimizing system efficiency. Additionally, the study of
fuels and combustion offers insights into energy sources, their properties, and their environmental
impacts, which are crucial for addressing modern engineering challenges.

The curriculum also emphasizes renewable energy, particularly solar technologies, to

encourage sustainable engineering practices. By integrating these concepts, the course prepares
students to contribute to the transition toward greener solutions. Overall, the syllabus is designed to
develop the analytical skills and practical knowledge necessary for solving real-world engineering
problems, equipping students to meet industry demands and excel in the field of Thermal
Engineering

2. Course Outcomes: At the end of the Course, the student will be able to:

CO-01
Identify the thermodynamic principles, processes and systems for the given well defined
thermodynamic problem.

CO-02 Determine the heat transfer (conduction, convection, and radiation) in various
engineering applications.

Department of Technical Education, Government of Karnataka 58

CO-03
Assess the fuel properties and combustion processes for the efficient use of different
fuels, including green fuels like hydrogen.

CO-04
Evaluate the performance of internal combustion engines and refrigeration systems
through practical experimentation and theoretical principles.

CO-05
Analyze power generation systems in thermal and renewable power plants for efficient
energy conversion and environmental sustainability.

3. Course Content

WEEK CO PO Theory Practice

Introduction to Thermodynamics
Definition of Heat, Temperature, Absolute ● Illustration of system and
Temperature, Specific Heat, Universal Gas surrounding using simple
Constant Basic Concepts: System, experiments / Virtual
Surroundings, and State Boyle’s law, simulations.
Charle’s Law and Gay Lussac’s law with ● Illustration of
expressions. Laws of Thermodynamics Thermodynamic equilibrium
Thermodynamic Properties Applications using simple experiments/
of Thermodynamics in Engineering Virtual simulations.
Simple problems on different laws ● Demonstrate the Boyles law
using an online simulation.
*Using Real-World Examples as ● Demonstrate the Charle’s law
Teaching Aids for Different using an online simulation.
Thermodynamic Systems ● Demonstrate the Gay-Lussac
law using an online
Closed System: A pressure cooker
simulation
1 1 1,2,5 trapping steam, a sealed can of soda at
room temperature, and a car engine ● Demonstrate the Laws of
cylinder during compression thermodynamics using
simple experiments or
Open System: A kitchen faucet with water virtual simulations[14,15]
flow, an air compressor taking in and
expelling air, and a radiator transferring
heat as fluid flows.

Isolated System: A thermos bottle keeping

coffee hot, an insulated ice chest preserving
cold items, and a sealed insulated lab
container

Identification of system boundaries in

industrial setups - Power plant,
Refrigeration , AC unit, IC Engine.

Department of Technical Education, Government of Karnataka 59

 Thermodynamic Processes
Introduction to Thermodynamic Processes ● Conduct an experiment to
Isochoric Process, Isobaric Process study the behaviour of
Isothermal Process, Adiabatic Process isochoric process using
Polytropic Process, Throttling Process computer simulations.
Combined Processes, and Real-World ● Conduct an experiment to
Applications study the behaviour of
Simple problems on different processes isobaric process using
computer simulations.
● Conduct an experiment to
*Using Real-World Examples as Teaching
study the behaviour of
Aids for Different Thermodynamic
Isothermal process using
Systems
computer simulations.
Isothermal Process: Boiling water in an ● Conduct an experiment to
open pot at a constant temperature, study the behaviour of
compression in a pressure cooker, and ice Isentropic process using
melting in water without temperature computer simulations. [15]
2 1 1,2,5
change.

Isobaric Process: Heating water in an

open pot, inflating a balloon, and baking a
cake in the oven at constant atmospheric
pressure.

Isochoric Process: Pressure changes in

sealed aerosol cans or bottles in a
refrigerator, heating a closed container,
and filament heating in a light bulb with
fixed volume.

Adiabatic Process: Rapid compression in

a bicycle pump, fire syringe demonstration,
and gas expansion from an aerosol can
showing temperature changes without heat
exchange.

Carnot Cycle ● Conduct the experiment to

Introduction to the Carnot Cycle, Ideal Gas, study the behaviour of
Assumptions, Four Processes of the Carnot Carnot Cycle using computer
3 1 1,2,5 Cycle, Efficiency of the Carnot Cycle, simulations[15]
Applications and Limitations of the Carnot
Cycle
Simple problem on Carnot efficiency
Heat Transfer ● Conduct the experiment to
Introduction to Heat Transfer determine the thermal
Conduction conductivity of a metal
4 2 3,4,6 Introduction to Heat Conduction, Fourier’s rod/thin slab/thick
Law of Heat Conduction, Thermal slab/cylindrical/fins and
Conductivity, One-Dimensional Steady- identify the factors
State Conduction, Factors affecting influencing thermal
Department of Technical Education, Government of Karnataka 60
 thermal conductivity, Applications of Heat conductivity.
Conduction in Engineering

*Using Real-World Examples as

Teaching Aids for Understanding
Conduction in Cooling and Heating

Metal cooking pans transferring heat to

food, heat spreaders in electronics
dissipating heat, thermal pads connecting
processors to heat sinks, and ice packs
cooling skin through direct contact.

Convection ● Conduct the experiment to

Introduction to Heat Convection, Types of study heat transfer in free
Convection: Natural and Forced Newton's convection and forced
Law of Cooling, Heat Transfer Coefficient, convection, and identify the
Factors affecting Heat Transfer Coefficient, factors influencing heat
Applications of Convection in Engineering transfer in each case.

5 2 3,4,6 *Using Real-World Examples as

Teaching Aids for Understanding
Convection in Cooling

Radiators dissipating engine heat, heat

sinks cooling electronics, ceiling fans
enhancing air circulation, and air
conditioners circulating cool air to lower
room temperature

Radiation ● Perform the experiment to

Introduction to Heat Radiation, verify the Stefan-Boltzmann
Fundamental Concepts of Radiation, Law by measuring the
Stefan-Boltzmann Law, Facors affecting radiant energy emitted from
Radiation and Emmisivity, Blackbody and a blackbody surface and
Gray body Radiation Applications of identify the factors affecting
Radiation in Engineering, radiation
● Conduct the experiment to
study heat transfer between
6 2 3,4,6 *Using Real-World Examples as surfaces with different
Teaching Aids for Understanding emissivities and identify the
Radiation in Cooling and Heating factors affecting emissivity.
Sunlight warming surfaces, infrared
heaters radiating warmth in a room,
cooling of hot engine parts by radiating
heat into the air, and solar panels
absorbing sunlight to generate electricity.

Department of Technical Education, Government of Karnataka 61

 Fuels and Combustion ● Conduct the experiment to
Types of fuels (fossil and renewable) measure the calorific value
Properties of fuel of fuel using a Bomb
Green fuels: hydrogen and alternatives Calorimeter or Boy's
7 3 1,2,7
(biofuels, ethanol, biodiesel). Calorimeter.
Applications and future trends in ● Perform the experiment to
hydrogen and green fuel technologies. determine the flash and fire
points of the given fuel.
Internal Combustion Engines ● Examine and identify the
Introduction to IC Engines parts of IC engine cut-
Types of IC Engines section models, and draw
Working Principle of IC Engines the valve timing diagram for
Two-Stroke and Four-Stroke Engines a 4-stroke diesel and petrol
Sustainability issues of using IC Engine engine.
*Identification of type of IC engines used ● Conduct the performance
in various applications - study of a single/multi-
8 4 1,2,7 Spark Ignition (SI) Engines- Passenger cylinder petrol or diesel
Cars, Motorcycles, Small Generators engine. and analyse the key
parameters.
Compression Ignition (CI) Engines-
Diesel Trucks, Agricultural Tractors, Power
Plants
Two-Stroke Engines-Lawn Mowers,
Chainsaws, Motorboats
Four-Stroke Engines- Passenger Cars,
Agricultural Tractors, Generators
Gas Turbines ● Conduct a virtual tour or
Introduction to Gas Turbines simulation-based
Open System Gas Turbines experiment on a gas turbine
Closed System Gas Turbines system to observe efficiency
9 4 5,6,7 Improving Efficiency in Gas turbines - improvement methods.
Intercooling, reheating, and regeneration ● Virtual Tour /Lab in Aero
techniques and Rocket Engine Studies
Aerojet Engines
Rocket Engines
Refrigeration ● Conduct the experiment to
Properties of Refrigerants find the COP (Coefficient of
Demerits of Freon series Refrigerants, Performance) of a given
Alternative Refrigerants. refrigeration system and
Coefficient of Performance (COP) identify the key components
Vapour Compression Refrigeration System involved.
10 4 2,4,6
Vapour Absorption Refrigeration System ● Examine and Identify the
*Identification of Refrigeration Systems Parts of a Domeatic
in varios applications Refrigeration Unit and
Vapour Compression Refrigeration Perform Service and
System Maintenance Procedures
Domestic Refrigerators, Commercial ●

Department of Technical Education, Government of Karnataka 62

 Freezers, Supermarkets, Walk-in Coolers,
Ice Makers, Air Conditioners, Wine Coolers
Vapour Absorption Refrigeration
System
Large-Scale Cooling Systems (Hotels,
Hospitals), Gas-Fired Refrigerators,
Refrigeration in Remote Areas, RV
Refrigerators, Absorption Chillers in
Industrial Applications

Air Conditioning ● Conduct the performance

Explain the Psychomertic terms study on an air conditioning
Introduction to Air Conditioning unit, focusing on cooling,
Types of Air Conditioning Systems humidification, and
Window Air Conditioner dehumidification processes.
Applications of Air Conditioning system ● Examine and identify the
11 3 2,4,6
key components of a
window air conditioning
unit and Perform the service
and maintenance of window
air conditioning unit.

Thermal Power Plant ● Conduct the study of a

Introduction to Steam Generation simple steam boiler model
Types of Boilers and identify the key
Babcock and Wilcox Boiler - its Mountings components.
12 5 5,6,7 and Accessories ● Participate in a visit or
Steam Cycle (Rankine Cycle) virtual tour of a thermal
Layout of Thermal Power Plant power plant and conduct a
case study on its operations.

Solar Energy ● Build a solar photovoltaic

Introduction to Solar Energy system using a solar panel
Solar Photovoltaic Systems and measure its output.
Solar Thermal Systems ● Conduct the visit to assess
Solar Power Plants the carbon footprint
Applications of Solar Energy reduction achieved by solar
panels and identify the key
Demonstration of a simple solar thermal components involved in the
13 5 5,6,7 system to heat water or fluids solar energy generation
process
● Perform the case study of
solar thermal power plants
including solar towers and
examine the critical
components that contribute
to the overall system
performance.

Department of Technical Education, Government of Karnataka 63

 4. References

Sl. Author Title of Books Publication/Year

No.

1 R.K. Rajput Thermal Engineering Laxmi Publications, 2010

2 R.N. Bahl Thermal Engineering Khanna Publishers, 2016

3 Enrico Fermi Thermodynamics Dover Publications, 1956

4 Hendrick C. Van Understanding Thermodynamics Dover Publications, 1983

Ness

5 Peter Atkins Laws of Thermodynamics Oxford University Press, 2010

6 Onkar Singh Applied Thermodynamics New Age International Publishers, 2014

7 ReccabManyala Solar Collectors and Panels, Theory InTechOpen, 2010

and Applications

8 Dipak Sarkar Thermal Power Plant Elsevier, 2015

9 J.G. Rau, D.C Environmental Impact Analysis McGraw-Hill, 1980

Handbook

10 J.A. Duffie& W.A. Solar Engineering of Thermal Wiley Publications; 3rd edition, 2006
Beckman Process

11 Werner Vogel and Large-Scale Solar Thermal Power WILEY-VCH Verlag GmbH & Co. KGaA,
Henry Kalb Technologies, Costs, and Weinheim, 2010
Development

12 Merala C. Pother, Thermodynamics for Engineers Schaum Outline Series, Tata McGraw-Hill,
Craig W. Somerton New Delhi, 2004

13 P.K. Nag Engineering Thermodynamics Tata McGraw-Hill, New Delhi, 1998

Department of Technical Education, Government of Karnataka 64

14 Gas Properties Simulation
Web Link:[Link]

15 Simulation of Thermodynamics First Law, Isothermal process and Carnot cycle

Web Link:
1. [Link]
2. [Link]
l#id_section_thermodynamics_gas_isothermal
3. [Link]
ml#id_section_thermodynamics_carnot

5. CIE Assessment Methodologies

Duratio
Sl. Test n Max.
CIE Assessment
No Week (minute Marks
s)
1. CIE-1Theory Test 4 90 50
Average of all
2. CIE-2 Practice Test 7 180 50
CIE=50 Marks
3 CIE-3 Theory Test 10 90 50

4. CIE-4 Practice Test 13 180 50

CIE-5 Portfolio evaluation of all practices
1-13 50
5 and activities through Rubrics
Total 50 Marks

6. CIE Theory Test model question paper

Program Mechanical Engineering Semester - III

I/II
Course Name Thermal Engineering Test
I
Course Code 25ME32I Duration 90 min Marks 50
Name of the Course Coordinator:
Note: Answer any one full question from each section. Each full question carries equal marks.
Q
Course
. Cognitiv Mar
Questions Outcom
N e Level ks
e
o
Section - 1
a. Identify the thermodynamic system in a pressure cooker and
Apply CO1 5
analyze the heat transfer involved in steam generation.
b. A gas is compressed isothermally from an initial volume of 2 m³
1
to a final volume of 1 m³. The initial pressure is 100 kPa. Apply CO1 5
Calculate the final pressure and work done.

Department of Technical Education, Government of Karnataka 65

 c. Identify the First Law of Thermodynamics in a steam turbine
Apply CO1 5
and analyze its energy transformation during operation
d. Analyze the thermodynamic process of heat exchange in an air
conditioning system. Identify whether it is an isothermal or Apply CO1 5
adiabatic process.
e. Identify Gay-Lussac's Law in a heated sealed container and
Apply CO1 5
analyze how pressure changes with temperature increase.
a. Identify an process in boiling water and analyze heat transfer at
constant temperature. Apply CO1 5

b. A gas at 100 kPa and 300 K is heated at constant volume until

the pressure reaches 400 kPa. Calculate the final temperature Apply CO1 5

c. Identify the process during balloon inflation and analyze the

2 constant pressure as volume increases. Apply CO1 5

d. Identify the process in an aerosol can and analyze the pressure

Apply CO1 5
change at constant volume when cooled.
e. Apply Gay-Lussac's Law to a pressure cooker. Explain how
temperature and pressure inside the cooker are related during Apply CO1 5
heating.
Section – 2
a. Identify the Law in a gas cylinder compression process and
analyze how pressure and volume change during compression. Apply CO1 5

b. A gas is heated at constant volume. The initial pressure is 500

kPa at 400 K. If the final temperature is 600 K, find the final Apply CO1 5
pressure.
c. Identify the concept of specific heat in heating materials and
3 analyze how it affects energy absorption. Apply CO1 5

d. A gas expands adiabatically. The initial pressure is 300 kPa, and

the final pressure is 150 kPa. The initial volume is 1 m³, and the Apply CO1 5
adiabatic index γ is 1.4. Calculate the final volume.
e. Identify process in a gas expansion valve and analyze the
Apply CO1 5
temperature change during the expansion process
a. A gas is heated at constant pressure. The mass of the gas is 2 kg,
and its specific heat capacity at constant pressure is 1.0 kJ/kg·K.
Apply CO1 5
The temperature increases from 350 K to 450 K. Calculate the
heat added.
b. Identify the process in a bicycle pump and analyze the
Apply CO1 5
temperature rise due to rapid compression.
c. In an isochoric process, the initial pressure is 100 kPa at a
4 temperature of 300 K. If the final pressure is 400 kPa, calculate Apply CO1 5
the final temperature.
d. A gas is compressed isothermally from a volume of 2 m³ to 1
m³. The initial pressure is 100 kPa. Calculate the final pressure Apply CO1 5
and the work done during the compression.
e. A Carnot engine absorbs 1000 kJ of heat from the high-
temperature reservoir and rejects 400 kJ to the low- Apply CO1 5
temperature reservoir. Calculate the work done and efficiency.
Note for the Course coordinator: Each question may have one, two or three subdivisions. Optional questions in each
section carry the same weightage of marks, cognitive level and course outcomes.

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

Department of Technical Education, Government of Karnataka 66

 7. CIE Practice Test model question paper

Program Mechanical Engineering Semester III

Course Name Thermal Engineering Test II

180
Course Code 25ME32I Duration Marks 50
min
Name of the Course Coordinator:

Note: Answer any one question from each section. Each question carries 25 marks
Mar
Questions CO
ks
Section-I
 Build a solar photovoltaic system using a solar panel and
measure its output.
OR
1. 1 4,5 25
 Conduct the experiment to find the COP (Coefficient of
Performance) of a given refrigeration system and identify the
key components involved.
Section-II
 Conduct the performance study on an air conditioning unit,
focusing on cooling, humidification, and dehumidification
processes.

2. OR 25
3,4
 Examine and identify parts of IC engine cut-section models.
Draw the valve timing diagram for a 4-stroke diesel or petrol
engine.

Scheme of Assessment
Safety Measures & Conduction - 10 Marks
Identification of Parts - 10 Marks
Observation & Recording - 10 Marks
50
Calculation & Analysis - 10 Marks
Interpretation of Results - 10 Marks

Total Marks - 50 Marks

Signature of the Course Coordinator Signature of the HOD

Department of Technical Education, Government of Karnataka 67

 8. Suggestive Activities for Tutorials:
 The students shall do minimum of one suggested activities
 List is an Example and not inclusive of all possible activities of the course.
 Student and Faculty are encouraged to choose activities that are relevant to the topic.

Sl.
Suggestive Activities for Tutorials
No.
Hybrid Engines
Activity: Conduct a case study on hybrid engine technology, focusing on the combination
01 of IC engines with electric motors.
Task: Create a PowerPoint presentation covering the design, working principles,
advantages, and future trends of hybrid engines. Ensure at least 10 slides are included.
Study of a Refrigeration System in a Local Repair Shop
Activity: Visit a refrigerator service shop and study the internal components of a
refrigeration unit. Record a video showing the compressor, condenser, evaporator,
02 expansion valve, and refrigerant flow.
Task: Create a PowerPoint presentation with a block diagram illustrating the system’s
layout, focusing on the refrigeration cycle and how each component contributes to the heat
transfer process.
Thermal Power Plant Visit
Activity: Visit a thermal power plant and document the overall power generation process,
from fuel combustion to electricity generation.
03
Task: Create a PowerPoint presentation focusing on the steam cycle, boilers, turbines, and
cooling towers. Include a detailed report on the control systems used, such as SCADA and
DCS.
Solar Power Plant
Activity: Visit a renewable energy or a solar power plant that utilizes CSP technologies.
04
Task: Prepare a PowerPoint presentation on Concentrated Solar Thermal Power
Technologies: Status of Concentrated Solar Thermal Power Plants in India.
study of IC Engine
Activity: Visit a automobile service station and study the components of a IC Engine.
05
Task: Create a PowerPoint presentation focusing on the IC Engine and how each
component contributes to the performance of IC engine.

Department of Technical Education, Government of Karnataka 68

 9. Rubrics for Assessment of Graded Exercises (Qualitative Assessment)

Sl. Dimension Unsatisfactory Needs Satisfactory Good Excellent Student’

No. Improvement s Score

(0-5) (6-10) (11-15) (16-20) (20-25)

1 Preparation Not prepared, Missing several Adequately Mostly Fully prepared, 20

lacks basic key items, limited prepared, prepared with complete
materials or understanding. missing minor all essential understanding
tools. items. tools. and tools.
2 Conduction Task not Major errors, Some minor Well executed, Flawlessly 20
/ Execution performed or significant impact inconsistencies, minor errors executed,
incomplete. on results. mostly correct. only. accurate and
precise results.
3 Quality of No quality Poor quality, Acceptable Good quality, High-quality 15
Work evident, major issues quality with minor flaws output, fully
significant issues affecting results. some defects. only. meets standards.
present.
4 Use of Lab No effective use Ineffective use, Basic use, with Good use of Excellent tool 20
Equipment of lab tools. risk of misuse. some tools, safe and usage, safe and
inefficiencies. mostly efficient.
accurate.
5 Lab Report Major sections Key sections Adequate, but Mostly Fully detailed 25
Submission missing or missing, poorly lacks some complete with report with
incomplete. detailed. detail. minor thorough
omissions. explanations.
Average Marks=(20+20+15+25+20)/5=20 20

Note: Dimension and Descriptor shall be defined by the respective course coordinator as per the exercises

10. SEE- Model Theory Question Paper

Program Mechanical Engineering Semester III

Course Name Thermal Engineering Marks
50
Course Code 25ME32I Duration
90
Min
Note: Answer any one full question from each section. Each full question carries equal marks.
Cogniti Course
Q Questions Mar
ve Outcomes
No ks
Levels

Section -1

a. Identify the system and surroundings in a steam boiler.

Explain how the First Law of Thermodynamics applies to Apply CO1 5+5
1 this system.
Department of Technical Education, Government of Karnataka 69
 b. Apply Boyle’s Law to a gas cylinder when the volume is
reduced by half. Calculate the resulting pressure.
a. Calculate the heat energy required to raise the
temperature of 5 kg of water from 25°C to 100°C. The
specific heat capacity of water is 4.18 kJ/kg·K.
Apply CO1 5+5
2 b. A Carnot engine operates between a high temperature of
600 K and a low temperature of 300 K. Calculate the
efficiency.
Section -2

a. Apply Fourier’s law of conduction to the heat transfer

through a metal rod. Identify the factors that affect the
rate of heat transfer. Apply CO2 5+5
3 b. Analyze the performance of a radiator using Newton’s law
of cooling. Explain how the heat transfer coefficient affects
cooling efficiency.
a. Identify the mode of heat transfer occurring in a hot water
radiator used for heating a room and appreciate how both
conduction and convection contribute to heatinga room. Apply CO2 5+5
4
b. Apply the Stefan-Boltzmann law to calculate the radiant
heat emitted by a blackbody surface.
Section -3

a. Apply the concept of biofuels to analyze how biodiesel can

be used in a diesel engine. Compare its efficiency to
conventional diesel. Apply CO3 5+5
5
b. Identify the type of engine used in a lawn mower. Explain
how this engine powers the mower.
a. Appreciate the environmental advantages of using
hydrogen as a fuel in IC engines.
b. Analyze the performance differences between two-stroke Apply CO3 5+5
6
and four-stroke engines in applications like motorcycles
and generators.
Section -4

a. Apply the basic principles of refrigeration to calculate the

COP of a refrigerator if 400 kJ of heat is removed using 100
kJ of work. Apply CO4 5+5
7
b. Identify the parts of a window air conditioner and
appreciate the role of each part in cooling the air.
a. Analyze the cause of reduced cooling in an air conditioning
system. Suggest possible solutions for issues .
b. Apply the principles of vapor-compression refrigeration to Apply CO4 5+5
8
explain how a cold storage unit maintains low
temperatures.
Section -5

a. Identify the main components of a solar power plant.

Explain how photovoltaic cells convert sunlight into
electrical energy. Apply CO5 5+5
9
b. Explain how improving the Rankine cycle's components
can enhance overall efficiency.

Department of Technical Education, Government of Karnataka 70

 a. Appreciate the role of solar photovoltaic cells in renewable
energy. Identify the advantages of solar power over coal-
based power plants. Apply CO5 5+5
10
b. Explain how the Brayton cycle work and analyze their
performance.

11. Equipment/software list with Specification for a batch of 30 students

Sl. No. Particulars Required Purpose/Experiment Quantity

1 Thermal Conductivity Apparatus (Metal Measure thermal conductivity 1 set

Rod/Slab/Thin Slab/Cylindrical)
2 Convection Heat Transfer Apparatus Study heat transfer in convection 1 set
3 Stefan-Boltzmann Apparatus Verify Stefan-Boltzmann Law 1 set
4 Emissivity Measurement Apparatus Measure heat transfer with different 1 set
emissivities
5 Bomb Calorimeter or Boy's Calorimeter Measure calorific value of fuel 1 set
6 Flash/Fire Point Apparatus Determine flash and fire points 1 set
7 IC Engine Cut-section Models Identify parts and draw valve timing 1 set
diagram
8 IC Engine Performance Test Rig Conduct performance study of IC engine 1 set
9 Refrigeration System Test Apparatus Measure COP of refrigeration system 1 set
10 Air Conditioning Unit Study performance of air conditioning unit 1 set
11 Simple Steam Boiler Model Study simple steam boiler operation 1 model
12 Solar Photovoltaic System Kit Build and measure output of solar panel 1 kit
13 Contactless (infrared) thermometer Educational / laboratory use 1
Temp. range = -50°C to 550°C
14 Non-contact (laser/infrared) tachometer to measure the rotational speed of machines 1
RPM range = 10 RPM to 99,999 RPM or engines

Department of Technical Education, Government of Karnataka 71

 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION

Program Mechanical Engineering Semester III

Course Name Fluid Power Engineering Type of Course Integrated
7Hr/Week =91 Hrs
Course Code 25ME33I Contact Hours
Teaching Scheme L: T:P [Link] Credits 5
CIE Marks 50 SEE Marks 50 (Practice)

1. Rationale: Fluid power is a term that describes the generation, control, and application of
smooth, effective power of pumped or compressed fluids (either liquids or gases) to provide force
and motion to mechanisms. With hydraulics, the fluid is a liquid (usually oil), whereas pneumatic
uses a gas (usually compressed air). This force and motion may be in the form of pushing, pulling,
rotating, regulating, or driving.
Students learn about the fundamental concepts important to fluid power, which
includes both pneumatic (gas) and hydraulic (liquid) systems. Students learn background
information about fluid power—both pneumatic and hydraulic systems—including everyday
applications in our world (bulldozers, front-end loaders, excavators, chair height lever adjusters,
door closer dampers, dental drills, vehicle brakes) and related natural laws.
The students are given exposure to building fluid power circuits and hence, on
completing this course, will be able to build Pneumatic and Hydraulic Fluid power system for
various applications.

2. Course Outcomes: At the end of the Course, the student will be able to:

CO-01 Recognize fundamentals of Fluid and Fluid Power and their applications.

CO-02
Conduct experiment to verify fluid properties, Pascal’s Law, Bernoulli’s Equation and losses
in pipes.
CO-03 Analyse the working of Hydraulic machinery and Determine its Performance.
CO-04 Identify basic components and functions of a Fluid power System

CO-05 Build and Execute Fluid Power systems for various application

Department of Technical Education, Government of Karnataka 72

 3. Course Content

WEEK CO PO Theory Practice

Introduction to Fluid power Study the following Fluid power

 Concept of Fluid power system and identify the
 Advantages and Disadvantages components and their functions
of Fluid power 1. Hydraulic lift truck.
2. Excavator
 Application of Fluid Power
3. Hydraulically powered robot
 Components of Fluid power
System- Hydraulic Power Study the following Fluid power
System, Pneumatic power system and identify the
System components and their functions
1 1 1,2,3&7 4. Bicycle Pumps
 Advantages, Disadvantages and
Applications of Hydraulic 5. Pneumatic Brakes
power systems and 6. Pneumatic torque wrench
pneumatic power system
 Fluid power Industry- Size and
scope, Future outlook
 Hydraulic Fluids- Functions,
Properties, Classification-
Liquid and Gases
Fluid Mechanics:  Conduct experiment to
 Physical Properties of Measure the Gage pressure
Hydraulic Fluids and units- using Manometer/Pressure
Specific Weight, Density, gage
Specific Gravity
 Pressure (Atmospheric, Gage Note: Real time situations can
and Absolute pressure), also be considered- Tire Pressure
Pressure measuring Devices Monitoringg, Engine Oil Pressure,
1,2,3&  Various types of energy gage pressure in hydraulic
2 1,2 cylinders, Monitoring air
7 present in Fluids, Total head
pressure in compressors
 Bulk Modulus, Viscosity and its
effect (Absolute and
Kinematic)  Determine Viscosity of Fluid
 Surface Tension and its effect using Redwood /Saybolt’s
on Fluids, Flow rate Viscometer
 Pascal's Law and its
Application, Conservation of
Energy
 Continuity Equation- Simple  Verify Pascals Law using hand
problems (Contd) operated Hydraulic Jack/
1,2,3& Bernoulli's Apparatus
3 1,2  Bernoulli's Equation –
7
Application - Simple  Verify Bernoulli's Equation
problems using Venturimeter

Department of Technical Education, Government of Karnataka 73

 Frictional Losses in Hydraulic  Conduct experiment to
Pipelines (No Derivations) determine the losses in Pipe
 Types of Flow, Dimensionless
number, Reynolds Number, N Note: Real time situations can
1,2,3& Darcy's Equation, Frictional also be considered
4 1,2
7 Losses in pipes, Water
Hammer in Pipes and its
prevention
 Simple Problems on
Frictional losses in pipes
Hydraulic Machineries  Conduct experiment to
Pumps measure the performance
 Concept, Pumping theory of Reciprocating Pump
 Positive displacement - and Centrifugal Pump
Principle, Types  Servicing of Centrifugal
 Non Positive Displacement - Pump and Submersible
1,2,4& Principle, Types Pump
5 3
7  Selection of Pumps
 Pump Efficiencies- Volumetric,
Mechanical, Overall Efficiency
 Centrifugal Pump and
Submersible Pump- Working
principle and Application
 Pump Cavitation
Turbines  Conduct experiment to
 Classification, Types determine the efficiency of a
Hydraulic Turbines- Impulse and Turbine (Pelton Wheel,
Reaction Turbines, Working, Francis Turbine, Kaplan
Applications,Selection of Turbines Turbine)
1,2,4&  Note: Can also use Virtual
6 3
7 Hydro-Electric Power Plant Lab
 Explain the Layout of a
Hydroelectric Power plant
 Explain thecomponents of
Hydro- Electric Power Plants &
their functions
Pneumatic Fluid Systems:
Identify the basic components of Pneumatic Power Systems with
Symbols and Application
 Air compressor
 Air Drier
1,2,4&
7 4  FRL Unit
7
 Reciprocating Compressor and Vane Compressor
 Pressure Relief valve and Pressure Regulating Valve (Pressure
control Valve- Pressure Reducing Valve, Pressure Intensifier
 Direction control Valves - 3/2 , 5/2, (Solenoid operated ,
Lever/Push button operated)

Department of Technical Education, Government of Karnataka 74

  Flow control Valve
 Check Valve
 Pneumatic Actuators- Linear, Rotary
 Shuttle Valve and its application in pneumatic circuit
 Quick Exhaust Valve and its application in pneumatic circuit
 Time Delay Valve and its application in pneumatic circuit
Build and Execute the following Pneumatic circuits
 Operation of a Single Acting cylinder using three-way valve
 Directional control of a double-acting cylinder using afour-way
1,2,3,4& /Five way valve.
8 5
7  Control Forward and Return speed of a double-acting cylinder
using two Non-return type flow control valves
 Continuous TO and FRO motion of a Double acting cylinder using
3/2 Roller operated valves
Build and Execute the following Pneumatic circuit
 Double-acting cylinder remotely operated through the use of an
airpilot-actuated DCV. ( For Automatic Opening and Closing of
Door by using double Acting Cylinder being controlled by 4/2 or
5/2 double pilot DC Valve)
1,2,3,4
9 5  Double-acting cylinder operated through the use of an air-pilot-
&7
actuated DCV for stamping operation.(5/2 Single pilot DCV)
 To press fit a pin to a hole with a precondition that while actuating
the cylinder, both the hands of the operator should be engaged
 Using limit switches to provide a timed cylinderextend and retract
cycle with the help of solenoid DCV
Build and execute the following Pneumatic circuit
 Design the pneumatic circuit diagram based on task given. A
double-acting cylinder is used to clamp components on a drill
machine. Upon operation of a push button and its in start
position, the clamping cylinder extends. Once the fully advanced
position is reached and finish button is pressed, the cylinder is
then immediately retract to the initial position. The cylinder
1,2,3,4
10 5 retraction is to be adjustable. A new start cycle is only possible
&7
after the cylinder has fully retracted.
 Two cylinders (Fig ) are used to transfer parts from a magazine
onto a chute. When a push button is pressed, the first cylinder
extends, pushing the part from the magazine and positions it in
preparation for transfer by the second cylinder onto the out feed
chute. Once the part is transferred, the first cylinder retracts,
followed by the second.

Department of Technical Education, Government of Karnataka 75

 A clamping system (double acting cylinder, (A) and drilling (double
acting cylinder, B) function as follows. When the switch is pressed,
the clamps will clamp and drill the work piece. Once completed, the
drill will stopped and reversed. Finally, the clamps will release the
work piece. The limit of start and extend position of the clamps and
drills are determined by the limit switch a0 and a1 for clamping
system and b0 and b1 for drilling respectively.
Hydraulic Fluid systems:
Identify the basic components of Hydraulic Power Systems with
Symbols and Application
 Hydraulic Fluid
1,2,3,4  Hydraulic pump- Gear Pump, Vane Pump, Lobe Pump
11 4
&7  Reservoir for hydraulic fluid

 Actuator- Cylinders and Hydraulic Motors

 Accumulator
 Directional control valve
 Seals
Build and Execute the following Hydraulic circuit using Hydraulic
kit/Simulator
 Design of hydraulic circuit for a drilling machine
(regenerative cylinder circuit for machine tool applications)
1,2,3,4 (hydraulic circuit for quick-return motion in machine tools)
12 5
&7
 Application of intensifier in punching press hydraulic circuit
 Hydraulic circuit for forklift application
 Hydraulic circuit for a surface grinding machine

Build and Execute Hydraulic/ Pneumatic fluid circuit for any one
1,2,3,4
13 5 Real time Application
&7
Ref: Suggestive Activities

Department of Technical Education, Government of Karnataka 76

 [Link]:

Sl
No Author Title of Book Publication/Year
7th Edition, Pearson New international
1 Anthony Esposito Fluid Power with applications Publication
1st Edition, Unit Penerbitan Publication,
2 DrMohd Elias Daud Pneumatic Circuit Design 2021
McGraw-Hill ProfessionalPublication,
3 M GalalRabie Fluid Power Engineering 2009
R K Hegde and Niranjan
4 Murthy Fluid Power Engineering Sapna book House
5 Ram Srivatsav Fluid Power Technology 2nd Edition, Standard Book House
Hydraulic Power Engineering; A
Practical Manual On The
Concentration And Transmission
6 George Croydon Marks Of Power By Hydraulic Machinery Forgotten Books Publication, 2018
Fluid Machinery: Hydraulic
7 Sadhu Singh Machines Khanna Publication House
Pneumatic Systems (Principles And
8 S Majumdar Maintenance) McGraw Hill Education

5. CIE Assessment Methodologies

Sl. Test Duration Max.

CIE Assessment
No Week (minutes) Marks
1. CIE-1Theory Test 4 90 50

2. CIE-2 Practice Test 7 180 50

Average of all
3 CIE-3 Theory Test 10 90 50 CIE=50 Marks
4. CIE-4 Practice Test 13 180 50
CIE-5 Portfolio evaluation of all practices
1-13 50
5 and activities through Rubrics
Total 50 Marks

Department of Technical Education, Government of Karnataka 77

 6. SEE – Practice Assessment Methodologies

Sl. Duration
SEE – Practice Assessment Max. Marks Min. Marks to Pass
No (minutes)
1. Semester End Examination-Practice 180 50 20

7. CIE Theory Test model question paper

Program Mechanical Engineering Semester - III

Course Name Fluid Power Engineering Test I
Course Code 25ME33I Duration 90 min Marks 50
Name of the Course Coordinator:
Note: Answer any one full question from each section. Each full question carries equal marks.
Q. Cognitive Course
Questions Marks
No Level Outcome
Section - 1
A) Which Fluid Power system is used in heavy Machinery? Justify
Apply 01 5
your statement.
B) Identify the components required and point 1of a Pneumatic
power Systems. What is the function of this component? Write the
role played by Direction control valve.

Apply 1,3 5

C) Which property of fluid helps in selection of good power

Apply 01 5
transmission oil? Justify your statement.
D) A Glass bottle filled with liquid will break at the bottom if a
stopper is forced into its open end. Which law is applied here? Apply 01 5
Why does the bottle break at the bottom?
E) How can air chambers or water hammer arrestors be used
to reduce the effects of water hammer in residential plumbing Apply 01 5
systems?
A) Which fluid power system is used in small robots ? Justify your
statement. Apply 01 5

B) Identify all the components of anhydraulic power Systems and

write their functions.
2
Apply 1,3 5

Department of Technical Education, Government of Karnataka 78

 C) What happens to the viscosity when the temperature acts upon
Apply 01 5
it and why?
D) On what principle does the syringe work? Discuss the
process of working. Apply 01 5

E) Explain how adjusting the valve closure speed can minimize

the risk of water hammer in industrial pipelines. Apply 01 5

Section – 2
A) Water flows through a horizontal pipe with two sections. In the
wide section of the pipe, the velocity of water is 2 m/s, and the
pressure is 150 kPa. The narrow section has half the diameter of Apply 01 10
the wide section. Find the velocity and pressure in the narrow
section.
3 B) Water flows out of a hole at the bottom of a large tank. The
water level is 5 mabove the hole. Find the velocity of water exiting Apply 01 10
the hole. Assume no energy loss due to friction.
C) A 50 m long pipe with a diameter of 0.2 m carries water at a
velocity of 3 m/s. The friction factor f=0.02. Find the head loss due Apply 01 05
to friction.
A) Water flows through a pipe with a change in elevation. At point
A, the velocity is 3m/s, the pressure is 200kPa, and the elevation
Apply 01 10
is 5m. At point B, the velocity is 6m/s, and the elevation is 10m.
Find the pressure at point B. Assume ρ=1000kg/m3.
B) A water jet exits a nozzle with a pressure of 200kPa. The
4
atmospheric pressure is 100kPa. Assuming no height difference Apply 01 10
and negligible friction, find the velocity of the jet.
C) A pipe is 150 m long and has a diameter of 0.15 m. Water flows
through it at a velocity of 1.5 m/s. The Darcy friction factor Apply 01 05
f=0.025. Calculate the head loss due to friction.
Note for the Course coordinator: Each question may have one, two or three subdivisions. Optional
questions in each section carry the same weightage of marks, cognitive level and course outcomes.

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

Department of Technical Education, Government of Karnataka 79

 8. CIE Practice Test model question paper

Program Mechanical Engineering Semester III

Course Name Fluid Power Engineering Test II

Course Code 25ME33I Duration 180 min Marks 50

Name of the Course Coordinator:

Note: Answer any one question from each section. Each question carries 25 marks

Questions CO Marks
Section-I
1. 1 a Why is oil often preferred over water in specific manometer 1,2 25
applications? Conduct an experiment to Measure the Gage pressure
using Manometer
bbWhat is the absolute pressure of the oil in the hydraulic press? Conduct experiment
to Measure the Gage pressure using Pressure gage?
c How to determine whether the flow is laminar or turbulent? Conduct
experiment to determine the viscosity of the given oil.
d How can Pascal's Law be demonstrated using a hand-operated hydraulic
jack, and how does the relationship between force, pressure, and
area validate the law in this setup?

Section-II
2. A An hydroelectric power plant for a river has a net head of 50 meters. 3 25
Select the type of turbine (Pelton, Francis, or Kaplan) that would
be most appropriate for this scenario. Conduct an experiment to
determine the efficiency of that turbine.
b A water treatment plant needs to pump water from a river to a
filtration system. The required flow rate is 200 liters per second.
Select the appropriate type of pump (centrifugal, reciprocating,
etc.) based on the given parameter. Conduct an experiment to
determine the performance of that Pump
Scheme of Assessment for Section I & II CO
a Selection of appropriate machinery /Answer to the appropriate
Question CO1 10 x 2
Note: Includes Aim of the practical, List of Components Required
b Conduction of experiment
Note: Includes Procedure writing, Observation, Tabularand formulas CO2 15 x 2
used, Execution and Result writing.
Total Marks 50

Signature of the Course Coordinator Signature of the HOD

Department of Technical Education, Government of Karnataka 80

 9 . Suggestive Activities for Tutorials:
 The students shall do minimum of one suggested activities
 List is an Example and not inclusive of all possible activities of the course.
 Student and Faculty are encouraged to choose activities that are relevant to the topic.

Sl.
Suggestive Activities for Tutorials
No.
Food industry uses for pneumatic systems include equipment for chopping, cutting, slicing
and dicing machines where pneumatic cylinders provide precise control of pressure and
01 motion to reduce damage to food items. Pneumatic-based cutting systems can be easily
adapted to process a variety of sizes, thicknesses and angles and are precise enough to
encourage uniformity.
Various segments of the manufacturing industry, robotic arms utilizing pneumatically
operated end of arm tooling (EOAT) can be applied to assembly, pick and place, machine
02
tending, and material handling tasks. The simple, lightweight design of pneumatic systems is
easier, often cheaper and less time consuming to maintain than electronic systems.
Automotive manufacturing relies on pneumatics for many operations, but one of the most
important is the painting and finishing process. Using compressed air as the power source, the
03 paint is sprayed though guns, robots or paint sprayers onto the prepared car body. In these
operations, the pneumatic system provides high-quality, moisture-free compressed air that
helps achieve a smooth, even factory finish.
Jet blast deflectors (JBDs) onboard aircraft carriers are raised and lowered by hydraulic
cylinders through mechanical linkage. Two hydraulic cylinders are attached to each JBD panel
shaft by crank [Link] shaft is rotated by the push and pull operation of the hydraulic
04
cylinders. Shaft rotation extends or retracts the linkage to raise or lower the JBD panels. This
operation is designed so that in the event of a failure of one of the hydraulic cylinders, the other
one will raise or lower the panels.
Pneumatic filling systems are used to dispense free-flowing materials or products such as
05
grains, weigh them and discharge them into packaging or process equipment.
06 Hydraulic circuit of dumpers
07 Hydraulic power steering
08 Hydraulic braking for automobiles

Department of Technical Education, Government of Karnataka 81

10 Rubrics for Assessment of Activity (Qualitative Assessment)

Sl. Dimension Unsatisfactory Need Satisfactory Good Excellent Students

No. Improvement Score
(0-5) (6-10) (11-15) (16-20) (21-25)

Some Components
Components are Some
Component Componentsarec are mostly Components
poorly selected or components are
Selection & ompatible, with compatible, are perfectly 25
incompatible with incorrectly sized
1 Sizing minor sizing with minor selected, well-
the system. or incompatible.
issues sizing issues. sized
The system
The design is design is
The system mostly clear, clear,
No system design The design is
System Design layout is with minor detailed, and
or layout diagram satisfactory but 20
2 & Layout incomplete, details accurate,
is provided. has errors.
unclear. missing or with a well-
errors. documented
layout
Comprehensi
The system
ve testing is
System The system performs
conducted,
No testing performance is performs well, well, meeting
and good
System Testing conducted, or below meeting basic basic
performance 20
3 & Performance system performs expectations, expectations expectations
expectations
poorly with several but with some with some
for efficiency
issues identified. issues room for
and
improvement.
reliability.
Documentatio
Documentatio n is mostly
No
Documentation n is mostly clear, but
Documentation documentation or
4 is incomplete, clear, But has some details Detailed and 15
& Reporting very poor quality
unclear some key data or phases are clear
documentation
missing missing or documentati
unclear. on
Average Marks = (25+20+20+15)/4 = 20/25

Note: Dimension and Descriptor shall be defined by the respective course coordinator as per the activities

11. SEE- Model Practice Question Paper

Program Diploma in Mechanical Engineering Semester IV

180
Course Name Industrial Automation Course Code: 25ME44P Duration
min
Note: Answer any one question from each section

Questions CO Marks

Section I
1. An hydroelectric power plant for a river has a net head of 50 meters. 3 25
Select the type of turbine (Pelton, Francis, or Kaplan) that would be

Department of Technical Education, Government of Karnataka 82

 most appropriate for this scenario. Conduct an experiment to
determine the efficiency of that turbine.
2. A water treatment plant needs to pump water from a river to a filtration
system. The required flow rate is 200 liters per second. Select the
appropriate type of pump (centrifugal, reciprocating, etc.) based on
the given parameter. Conduct an experiment the performance of the
selected pump.
Section II

3. For the given Application, Identify the components and Build and 4,5 25
Execute a Pneumatic Power system.
4. For the given Application, Identify the components and Build and
Execute an Hydraulic Power system.
Scheme of Assessment CO Marks

a Selection of appropriate machinery/Identify the component 3/4 5*2

b Tabular column with formula/ Build the circuit 3/5 10*2
c Execute + Result/Inference 3/5 10*2
Total Marks 50

2) Signature of the Examiner 2) Signature of the Examiner

12 Equipment list with Specification for a batch of 30 students

Sl. No. Particulars Specification Qty.

U-tube manometer with mercury as the
working fluid, Measurement range: 0-
500 mm Hg, Tubing material: PVC for
Manometer setup to measure gas flow compatibility, Connection: 1/8-
01 02
Pressure inch barbed fittings fortight sealing,
Environment: Controlled at 25°C to
ensure stable readings.

Type: Bourdon’s tube pressure gauge,

Range: 0–10 bar (0–145 psi),
Accuracy: ±1.0% of full scale, Dial Size:
Bourdon’s tube pressure 100 mm for easy readability, Material-
gauge set up to measure Tube: Stainless steel (316L), Case: IP67- 02
02
rated stainless steel, Connection: 1/4"
Pressure
NPT bottom-mounted, Filling: Glycerin
for vibration damping, Temperature
Range: -20°C to 60°C (-4°F to 140°F).

Type: Hand-operated hydraulic bottle

03 Hand operated Hydraulic Jack jack, Load Capacity: 10 tons, Stroke: 02
150 mm, Material: Steel frame with a
chrome-plated piston rod, Hydraulic
Department of Technical Education, Government of Karnataka 83
 Fluid: ISO VG 46 oil, Pressure Rating:
Up to 700 bar, Base Size: 200 mm x
150 mm, Safety Features: Overload
protection, pressure relief valve, and
locking mechanism, Accessories:
Integrated pressure gauge, extension
rods, and carrying handle.
For light oils (low viscosity), 20–2,000
Redwood seconds, Standard small
orifice (1.62 mm diameter),Ambient to
100°C (standard) or up to 150°C
Redwood Viscometer (extended range), 1: 50 ml, Electrically 02
04
heated with temperature control, Two
calibrated thermometers: one for bath
and one for oil sample,220–240 V AC,
50/60Hz,Accessories:Stopwatch, Brass
or stainless steel flow cup.
Meets ASTM D88, ASTM D244, and IP 71
standards for Saybolt viscosity tests,
Suitable for light and heavy oils, with
viscosity ranging from 30 to 20,000
Saybolt Universal Seconds (SUS),Material:
Stainless steel bath with corrosion
resistance, Capacity: Typically 5–10 liters
05 Saybolt’s Viscometer 02
for uniform heating, Finish: Polished or
powder-coated for durability,Ambient to
100°C,Electrically heated, equipped with
an immersion heater and digital
temperature controller, Accuracy: ±0.1°C,
60 mL for a single test run, 220–240 V AC,
50/60 Hz
Venturi Tube: Transparent acrylic,
Pressure Tapping: Multiple
measurement points, Manometer:
Vertical tubes for pressure readings,
Bernoulli's Apparatus Flow Measurement: Rotameter, Water 02
06
Supply: Reservoir with flow control,
Dimensions: ~1000 mm (L) × 300 mm
(W) × 600 mm (H), Fluid: Clean water,
Flow Range: 0.1–2 L/min, Base: Steel
or aluminum frame.
Venturi Tube: Transparent, with
converging and diverging sections,
Pressure Tapping: Multiple points
before, at and after the throat for
pressure readings., Manometer: U-tube
or digital for pressure measurement,
07 Venturimeter setup Flow Measurement: Rotameter (0.1–2 01
L/min), Water Supply: Reservoir with
flow control, Dimensions: Venturi tube
~500–1000 mm, overall system ~1000
mm (L) × 300 mm (W) × 600 mm (H),
Fluid: Clean water, Flow Range: 0.1–2
L/min, Base: Steel or aluminum frame

Department of Technical Education, Government of Karnataka 84

 Pipe: Transparent, 10–30 mm
diameter, 1–2 meters long, Flow
Control: Adjustable valve/pump,
Pressure Measurement: Manometers
08 Friction in pipes setup 01
at key points, Flow Measurement:
Rotameter (0.1–2 L/min), Fluid: Clean
water, Flow Range: 0.1–2 L/min, Base:
Steel or aluminum frame.
Pelton Wheel: With multiple cups
(buckets), made of durable material
(e.g., aluminum or acrylic), Nozzles:
Adjustable to control water flow and
direct jets to the wheel,Flow Control:
Valve for regulating water flow, Flow
09 Pelton Wheel Measurement: Rotameter or flow 01
meter, Speed Measurement:
Tachometer to measure wheel rotation
speed, Wheel Diameter: 100–300 mm,
Flow Rate: 0.1–2 L/min
(adjustable),Base: Steel or aluminum
frame for stability and portability.
Turbine Runner Diameter: 100–300
mm,Flow Rate: 0.1–5 L/s (adjustable),
Power Output: 0.1–2 kW, Water
10 Francis Turbine Supply: Reservoir with controlled 01
pump, Speed Control: Adjustable for
load testing, Dimensions: 1–2 meters
long (bench-mounted setup)
Turbine Runner Diameter: 100–300
mm, Flow Rate: 0.1–5 L/s (adjustable),
Power Output: 0.1–2 kW, Water
Supply: Reservoir with controlled
11 Kaplan Turbine pump, Speed Control: Adjustable for 01
load testing, Dimensions: 1–2 meters
long (bench-mounted setup),
Adjustable Blades: To control water
flow and optimize turbine performance
Discharge Rate: 0.1–2 L/min
(adjustable), Pressure Range: 0–10
bar, Stroke Length: 50–150 mm, Pump
Speed: Adjustable (manual or
motorized), Power: Typically 0.1–0.5
12 Reciprocating Pump 01
kW, Material: Stainless steel or durable
plastic for easy maintenance,
Dimensions: Compact, typically 400–
600 mm in length, Water Supply:
Reservoir or tank with controlled flow

Department of Technical Education, Government of Karnataka 85

 Flow Rate: 0.1–5 L/s (adjustable),
Head: 1–10 meters, Power Output:
0.1–2 kW, Inlet/Outlet Diameter: 20–
50 mm, Water Supply: Reservoir with
13 Centrifugal Pump controlled pump, Speed Control: 01
Adjustable for varying load conditions,
Dimensions: Compact, typically 0.5–1
meter in length, Material: Durable
plastic or stainless steel for easy
handling and observation
Air Pressure Range: 0–8 bar, Flow
Rate: 0.1–2 L/s (adjustable),
Compressor Power: 0.1–1 kW,
Components: Air
compressor,Pneumatic cylinders (single 01
14 Pneumatic Kit
and double-acting), Control valves
(directional and flow control), Pressure
regulators and gauges, Dimensions:
Compact, typically 1–2 meters in length,
Power Supply: 220V AC, 50/60 Hz,
Material: Range:
Pressure Durable0–10
plastic
baror(adjustable),
metal for
ease of
Flow use in
Rate: classroom
0.1–5 L/min setups
(adjustable),
Reservoir Capacity: 5–10 liter,
Components: Hydraulic pump
15 Hydraulic Kit (manual/electric), Pressure relief valve, 01
Flow control valve, Cylinders and
actuators, Power Source: Electric
motor or hand pump, Dimensions:
Compact, typically 1–2 meters long

Department of Technical Education, Government of Karnataka 86

 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION

Program MECHANICAL ENGG Semester IV

Programming Concepts in
Course Name Type of Course Integrated
Mechanical Engineering
Course Code 25ME34I Contact Hours 91 Hrs/Sem

Teaching Scheme L: T:P Credits [Link]

CIE Marks 50 SEE Marks 50 (Practice)

8. Rationale:

Incorporating programming into the mechanical engineering curriculum prepares

students for careers in emerging fields such as robotics, automation, and mechatronics. Students
will gain hands-on experience, enabling them to apply theoretical concepts to real-world
challenges. Understanding programming concepts fosters critical thinking and analytical skills,
essential for any engineer. Furthermore, proficiency in programming enhances collaboration with
software engineers and data scientists in multidisciplinary projects. As industries increasingly
rely on data-driven decision-making, programming becomes a key competency for mechanical
engineers. Ultimately, this course equips students with the necessary tools to innovate and excel
in a technology-driven engineering landscape.

2. Course Outcomes: At the end of the Course, the student twill be able to:

CO-01 Use appropriate syntaxes while writing program.

CO-02 Import and export engineering data between programming environments and
spreadsheet applications for various engineering problems.
Apply python programming to solve various quality control problems in the field of
CO-03
mechanical engineering.
Apply Raspberry Pi hardware interfacing with python software to various
CO-04 mechanical systems such as automation, robotics, control systems, and data
collection.

Department of Technical Education, Government of Karnataka 87

3. Course Content

WEEK CO PO Theory Practice

Algorithms and Flow Charts
 The Importance of Write the Algorithm and flow Chart for
Programming in Solving the following
Engineering Problems  Convert Fahrenheit to Centigrade
 Importance of Python in  Efficiency of and simple machine
1 1 1,2
Problem Solving over other  To generate the multiplication table
programing languages. for the number 5. (Control Loop)
 Algorithms – Steps/Procedures  Finding the Max of three forces
 Flowcharts – Symbols and (Decision)
Methodology
Introduction to Python and Basic
Constructs
 Write a Python program to accept
 Introduction to Python and its
user input and perform arithmetic
environment (e.g., Anaconda,
operations (addition, subtraction,
Jupyter Notebook, IDEs like
etc.)
PyCharm)
 Calculate the output speed and
 Basic syntax, variables, and data
2 1 1,2 torque in a gear system based on
types (int, float, string, boolean)
user-inputted values for input
 Input/ Output operations
speed, input torque, and gear ratio
(input(), print())
using basic operators.
 Type conversions (int(), float(),
 Practice problems on type
str())
conversions and working with
 Basic arithmetic and assignment
variables.
operators.
 Write a Python program to
Control Structures (Conditional
determine if a number is even or
Statements and Loops)
odd.
 Create a program that uses a for
 If-else conditions, elif
loop to print multiplication tables.
3 1 1,2,4 statements
 Write a Python program to calculate
 Nested if statements
the factorial of a number using a
 for loop and while loop
while loop.
 Loop control statements
 Practice problems using if-else and
(break, continue, pass)
loops.
Functions and Modules  Write a Python program that
defines a function to calculate the
 Function definition, parameters, area of a circle.
and return values  Create a program to find the
 Scope of variables (local vs greatest common divisor (GCD) of
global) two numbers using a function.
4 1 1,2,4
 Lambda functions  Explore lambda functions by
 Built-in functions vs. user- creating small one-liners for tasks
defined functions like squaring a number.
 Importing and using modules  Write a Python program to use the
(math, random, etc.) math module for trigonometric
calculations.
Department of Technical Education, Government of Karnataka 88
  Create a Python program that stores
Data Structures (Lists, Tuples,
names of students in a list and
and Dictionaries)
performs operations like adding,
 Lists: creation, indexing, slicing,
removing, and sorting.
adding/removing elements
 Write a program that converts a list
 List methods (append(),
of temperatures from Celsius to
remove(), sort (), etc.)
Fahrenheit.
5 1 1,2,4  Tuples: definition and
 Create a Python dictionary for
immutability
storing student records (name, age,
 Dictionaries: creation,
and grade) and write functions to
accessing, adding, and
add and remove entries.
removing key-value pairs
 Write a program that uses tuples to
 Iterating over lists, tuples, and
store and display coordinates in 2D
dictionaries
space.
 Write a Python program to read
File Handling and Exception
from a file and count the number of
Handling
words in it.
 File operations: reading from
 Create a Python program that
and writing to files (open(),
writes a list of random numbers to a
read(), write(), close())
file and reads them back.
6 2 1,2,4  Working with text files and CSV
 Write a program to handle division
files
by zero using try-except blocks.
 Exception handling: try, except,
 Write a Python program to read
finally
data from a CSV file and perform
 Common exceptions and error
basic operations like counting the
handling techniques
number of rows.
 Write a Python class to represent a
Object-Oriented Programming
Car with attributes like model, year,
(OOP)
and color. Include methods to start,
stop, and display car details.
 Introduction to OOP concepts:
classes and objects  Create a program that implements
inheritance with a base class Animal
7 2 1,2,4  Class attributes, methods, and
and derived classes Dog and Cat.
the __init__ method
 Write a Python program that
 Inheritance and method
demonstrates method overriding.
overriding
 Develop a Python class for a bank
 Encapsulation, abstraction, and
account that supports deposit,
polymorphism
withdrawal, and balance inquiry.
Statistical Quality Control (SQC)
Basic Concepts

 The Role of Quality Control in

Modern Manufacturing  Develop the Python program to
 Advantages of Python in calculate Sample Average ( ) &
8 2,3 1,2,4
Quality Analysis and Control Sample Range (R) for the given data
 Introduction to SQC, Benefits of and Plot X bar and R Charts for the
SQC given data using Matplotlib.
 Techniques of SQC – Process
control and Product control
 Control Charts – for variables
Department of Technical Education, Government of Karnataka 89
 (X bar and R Charts), Fraction
defective (p-Chart), Number of
defects per unit (C-Chart)

Introduction to Statistical
Quality Control (SQC):


Calculate the Sample Average  Calculate mean, variance, and
( ), Average of Average ( ), standard deviation using Python.
 Sample Range (R), Average of  Generate X-bar and R control charts
9 2,3 1,2,4
Range (R), from sample data using Matplotlib.
 Standard Deviation (σ)  Identify in-control and out-of-
 Process Capability (Cp), control points.
Process Capability Index
(Cpk)for ongoing process
study.
Hypothesis Testing and TQM -


Hypothesis Testing- t-test,
ANOVA
 Design of Experiments (DOE)  Generate python code to plot
10 3 1,2,4  Quality Improvement Tools - different Quality control tools for
Pareto Chart, Fishbone the given data.
Diagram, Flowchart
 Continuous Improvement-Lean,
Six Sigma, and Total Quality
Management (TQM)
Finite Element Analysis (FEA) –

Introduction to Finite Element

Method.
 General steps of the finite  Write a python code to plot the
element method. stress distribution in the plate at
various lengths along the bar
11 3 1,2,4  Engineering applications of
finite element method.  Write a python code to compare
 Advantages of the Finite and plot the stress distribution in
Element Method. the plate with and without hole.
 Stiffness Matrix of a Bar
Element - Global Stiffness
Matrix, Properties of stiffness
matrix.
Introduction to Raspberry Pi
Practice -
and Setup
Motor Control and Automation
 Overview of Raspberry Pi
Motor Driver Circuits
12 4 1,2,4 hardware (Model types, GPIO
 Controlling DC motors using L298N
pins)
motor driver with Raspberry Pi
 Setting up Raspberry Pi (OS
 Building simple automated systems
installation, booting up,
like a fan or water pump controller
network setup)
Department of Technical Education, Government of Karnataka 90
 Raspberry Pi GPIO (General
Purpose Input/Output) pins
 Using breadboards, jump wires,
and sensors with Raspberry Pi
Sensor Integration and Data
Collection
 Interfacing sensors like
temperature, humidity,
pressure, and motion with
13 4 1,2,4 Raspberry Pi.  Building a simple robot using
 Using common sensors such as Raspberry Pi, motors, and sensors
DHT11
(humidity/temperature),
BMP180 (pressure), PIR
(motion).

4. References:

Sl.
Author Title of Books Publication/Year
No.
[Link] , Dr. S. Fundamentals of Python
1. Shashwat Publication, 2023
Bhargavi Programming
Python for Mechanical and
2. Alex Kenan 2020
Aerospace Engineering
Sinan Kalkan, Onur T. Programming With Python Springer-Nature New York Inc,
3.
Sehitoglu, Gktrkoluk for Engineers 2024
4. Luciano Ramalho Fluent Python O'Reilly Media, Inc, USA, 2015
5. Wesley J. Chun Core python programming Prentice Hall PTR, 2006
Alex Bradbury and Ben Learning Python with
6. John Wiley & Sons Inc, 2014
Everard Raspberry Pi
Getting Started With O'Reilly Media, Incorporated,
7. Matt Richardson
Raspberry Pi 2012
5. CIE Assessment Methodologies

Duration Max
[Link] CIE Assessment Test Week (minutes) marks
1. CIE-1 Theory Test 4 90 50
2. CIE-2 Practice Test 7 180 50 Average of all
3 CIE-3 Theory Test 10 90 50 CIE=50
4. CIE-4 Practice Test 13 180 50 Marks
CIE-5 Portfolio evaluation of
5. all practices and activities – 25 1-13 50
Marks throughRubrics
Total 52 Marks

Department of Technical Education, Government of Karnataka 91

6. SEE – Practice Assessment Methodologies

Duration Max Min marks to

[Link] SEE – Practical Assessment
(minutes) marks pass
1. Semester End Examination-Theory 180 50 20

7. CIE Theory Test model question paper

Program Mechanical Engineering Semester- 3

Course Name Programming Concepts in Mechanical Engineering Test I
Course Code 25ME34I Duration- 90 min Marks-50
Name of the Course Coordinator:
Note: Answer any one full question from each section. Each question carries equal marks.
Q. No Questions CL CO Marks
Section - 1
f) Draw a flowchart to represent the algorithm for checking if a given number
is a prime number. Include decision points and the necessary steps for
input, process, and output.
g) Discuss the importance of breaking down a problem into smaller steps
when creating an algorithm. How does this help in developing efficient and 7+6+6
1 clear solutions to engineering challenges? Apply CO1 +6 =
h) In Python, how do you declare a variable to store a person's name and their 25
age? What data types would be appropriate for these variables, and why?
i) Enumerate the purpose of the input () function in Python? Provide an
example of how it can be used in a simple engineering program to get user
input
a) Draw a flowchart to find the maximum of three forces (F1, F2, F3), we
compare the values step by step.
b) Compare how Python, with its libraries, would be more advantageous
compared to other programming languages like C++ or Java.
7+6+6
c) Discuss the boolean variable in Python. In which type of engineering
2 Apply CO1 +6 =
problem would you use a boolean data type, and how would it help in
25
decision-making?
d) In Python, if a user enters a decimal number as input, but the program
requires an integer for further calculations, how would you handle this
situation using type conversion? Provide a simple code example.
Section - 2
f) In an engineering application where the user inputs a product's weight, you
need to determine if the weight is acceptable for transport. Write an if-
else condition to check if the weight is within an acceptable range.
7+6+6
3
g) Differentiate between the break, continue, and pass statements in
Apply CO1 +6 =
Python? Explain with examples how you would use each one in an 25
engineering program that processes a list of machine components to check
for faults.
h) Describe the role of function parameters and return values. Provide an
Department of Technical Education, Government of Karnataka 92
 example where a function takes different parameters to calculate the cost of
various materials.
i) Differentiate between built-in functions and user-defined functions in
Python? Provide an example where a built-in function is more efficient than
writing a custom user-defined function
f) You are programming a system that checks the pressure in a pipeline and
outputs warnings based on low, medium, or high-pressure readings. How
would you use elif to handle these multiple conditions?
g) Differentiate between a for loop and a while loop in Python? Provide an
example of when you would use a for loop versus a while loop in an 7+6+6
4 engineering context. Apply CO1 +6 =
h) Explain why user-defined functions are often necessary in programming, 25
even when built-in functions are available.
i) Differentiate between local and global variables? Provide an example of
when you would use a global variable and when a local variable would be
more appropriate in an engineering application.
Note for the Course coordinator: Each question may have two, three, four and five subdivisions. Optional
questions in each section carry the same weightage of marks, cognitive level and course outcomes.

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

7. CIE Practice Test model question paper

Program Mechanical Engineering Semester 3

Course Name Programming Concepts in Mechanical Engineering Test II
Course Code 25ME34I Duration 180 min Marks 50
Name of the Course Coordinator:
Note: Answer any one full question from the following
Questions CO Marks
1. a. Write the Algorithm and flow Chart to Convert Fahrenheit to Centigrade CO1
b. Write a Python program to determine if a number is even or odd. C01
5+5+10
c. Create a Python program that uses a for loop to print multiplication tables. CO1
+15+15
d. Create a Python program that writes a list of random numbers to a file CO1
= 50
and reads them back. Marks
e. Create a program to find the greatest common divisor (GCD) of two
numbers using a function. CO2
CO1
2. a. Write the Algorithm and flow Chart to find out Efficiency of and simple
machine CO1
b. Write a Python program to use the math module for trigonometric
calculations. CO1 5+5+10+
c. Create a Python dictionary for storing student records (name, age, and 15+15=
grade) and write functions to add and remove entries. CO2 50
d. Write a Python class to represent a Car with attributes like model, year, Marks
and color. Include methods to start, stop, and display car details. CO2
e. Write a Python program to read data from a CSV file and perform basic
operations like counting the number of rows.

Department of Technical Education, Government of Karnataka 93

 Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

9. Suggestive Activities for Tutorials:

 The students shall do minimum of one suggested activities

 List is an Example and not inclusive of all possible activities of the course.
 Student and Faculty are encouraged to choose activities that are relevant to the topic.

[Link]. Suggestive Activities for Tutorials

Using Python to Plot the stress-strain curve for a given material, based on data provided from
01 tensile testing.
Create a simple robot that avoids obstacles using an ultrasonic distance sensor using Raspberry
02 Pi and Python.
Design a real-time monitoring of motor speed for a mechanical system using Raspberry Pi and
03 Python.
Build a simple smart home automation system that controls mechanical devices like lights, fans, or a
04 security camera using Raspberry Pi and Python

10. Rubrics for Assessment of Graded Exercises (Qualitative Assessment)

Need
Unsatisfactory Satisfactory Good Excellent
Sl. Improvement Student
Dimension
No. Score
(0-5) (6-10) (11-15) (16-20) (20-25)

Fully prepared
Lacks several Adequately Mostly
Not with all
important prepared but prepared
1 Preparation prepared necessary 20
materials or missing key with minor
at all materials and
tools items omissions
tools
Some Test or task
Major errors Minor errors
Execution/ inconsistencie performed
Task not affecting in execution,
2 Implement s or flawlessly with 20
executed results or but overall
ation inaccuracies precision and
functionality effective
present accuracy
Poor quality, Acceptable High-quality
No quality Good quality
Quality of major flaws quality with output, meets or
3 demonstra with minor 15
Work impacting noticeable exceeds
ted flaws
functionality defects standards
Mastery of tools
Use of No proper Weak use of Good use of
Basic use of and techniques
Tools/ tool use tools, tools, minor
4 tools, some demonstrated 20
Technique demonstra significant issues with
inefficiencies safely and
s ted risks noted technique
effectively
Most All required
Practical Major Major sections
Some sections sections are sections are
Record sections are missing or
5 are included, complete included and 25
submissio are not poorly
but lack detail. with minor thoroughly
n addressed. addressed.
omissions. detailed.
Average Marks=(20+20+15+20+25)/5=20 20

Department of Technical Education, Government of Karnataka 94

 Note: Dimension and Descriptor shall be defined by the respective course coordinator as per the activities

11. SEE–Model Practical Question Paper

Program Mechanical Engineering Semester 3
Course Name Programming Concepts in Mechanical Engineering Marks 50
180
Course Code 25ME34I Duration
Min
Note: Answer any one full question. Each full question carries equal marks.
Cognitive Course
Q No Questions Levels Outcomes Marks
Section -1
[Link] a Python class to represent a Car with attributes
like model, year, and color. Include methods to start, CO2
10
stop, and display car details.
b. Develop the Python program to calculate Sample
1 Average ( ) & Sample Range (R) for the given data and Apply
CO3
Plot X bar and R Charts for the given data using 20
Matplotlib.
c. Write a program to Build automated water pump CO4
controller using Raspberry Pi. 20

a. Create a Python program that stores names of

students in a list and performs operations like adding, CO2 10
removing, and sorting.
b. Calculate mean, variance, and standard deviation
2 Apply CO3 20
using Python and Generate X-bar and R control charts
from sample data using Matplotlib.
c. Write a program to Control DC motors using L298N CO4 20
motor driver using Raspberry Pi.

13. Equipment/softwarelistwithSpecificationforabatchof30students

[Link]. Particulars Specification Quantity

iPython, Jupyter, spider,
01 Python Editors 20
PyCharm , googleCoLab
02 Desktop Computers Latest 30
(Raspberry Pi OS Lite or
03 Raspberry Pi OS 30
Desktop version)
Breadboards and Electronic
Components (1 set per group of 2
students) –
 Breadboard (15 units)
04 - 30
 Size: Full-size (830 points)
 Connector Type: 0.1-inch
spaced pins
 Jumper Wires (30 sets)

Department of Technical Education, Government of Karnataka 95

  Length: 10cm to 30cm
 Type: Male-to-male, male-
to-female, female-to-female
 LEDs (30 units)
 Type: 5mm standard
 Colors: Red, Green, Blue
 Resistors (Assorted Pack, 30
sets)
 Resistance: Common values
(220Ω, 330Ω, 1kΩ, 10kΩ)
 Sensors (1 set per group of 2
students)
 Temperature Sensors (e.g.,
DHT11 or DS18B20)
 Motion Sensors (PIR
Sensors)
 Distance Sensors
(Ultrasonic HC-SR04)

Department of Technical Education, Government of Karnataka 96

 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION
Curriculum Structure
IV Semester Scheme of Studies- Mechanical Engineering
CIE Theory SEE Practice SEE

Total Contact
Hours/week
Department

Hours per week

Teaching

Marks Marks Marks

Credits
Total
Sl. Course Code Course Name Marks
L T P Max Min Max Min Max Min
No.

Integrated Courses

1 Product design, Drawing and 4 0 4 8 6 50 20 50 20 - - 100

ME 25ME41I
development

2 ME 25ME42I Operations management 4 0 4 8 6 50 20 50 20 - - 100

ME Machine Tool Technology & 3 0 4 7 5 50 20 - - 50 20 100

3 25ME43I
CNC Programming

ME Elements of Industrial 3 0 4 7 5 50 20 - - 50 20 100

4 25ME44I
Automation
Audit Course
Kannada –II
-
5 KA 24KA41T 2 0 0 2 2 50 20 - - - 50
(ಸಾಹಿತ್ಯ ಸಿಂಚನ-II/ಬಳಕೆ ಕನನಡ-II)
-
Total 16 0 16 32 24 250 - 100 100 - 450
 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION

Program MECHANICAL ENGG Semester IV

Course Name Product Design, Drawing Type of Course Integrated
and Development
104 Hours/SEm
Course Code 25ME41I Contact Hours
Teaching Scheme L: T:P [Link] Credits 6
CIE Marks 50 SEE Marks 50 (Theory)

1. Rationale - This course provides a holistic view of product design, covering fundamental
principles, methodologies, and contemporary trends. Students will gain insights into user-centered
design, materials and manufacturing processes, and sustainability considerations.
Effective product design requires clear communication of ideas. This syllabus focuses on
developing visualization skills, teaching students how to create detailed sketches, technical
drawings, and digital models that effectively convey design intent to various stakeholders hence this
course emphasizes the importance of fundamental drawing techniques and tools, enabling students to
accurately communicate their ideas visually. Mastery of these skills is crucial for translating concepts
into design specifications. By combining theoretical knowledge with practical application, the syllabus
encourages students to engage in hands-on drawing and prototyping activities. This approach
reinforces learning and fosters a deeper understanding of the design process.

2. Course Outcomes: At the end of the Course, the student will be able to:

CO-01 Use Principles of product design considering Strength, Aesthetic and Ergonomic.

Design simple machine elements like fasteners, shafts, couplings and knuckle joints
CO-02 using design data inputs.
Prepare CAD Part and Assembly drawings for couplings and knuckle joints based on
CO-03 designed parameters.

CO-04 Identify Geometric Dimension and Tolerance of the machine drawings.

Note: Course Co-coordinators can redefine their Course Outcomes as per their TLP

Department of Technical Education, Government of Karnataka 98

3. Course Content
WEEK CO PO Theory Practice
Introduction to Machine / Product
design
 Interpret course related SI units
 Introduction to product design and
and their conversions.
development, stages of new product
 Understanding the normal
development. Product Life Cycle.
values of ultimate tensile
 Types of design, necessity of design,
strength, yield strength, density,
1 1 1 Comparison of designed and
modulus of elasticity and
undersigned work, Design procedure,
Poisson’s ratio of commonly
Characteristics of a good designer
used materials.
 Design terminology: factor of safety,
 Identify the normal values of
factors affecting factor of safety, stress
factor of safety for different
concentration, methods to reduce
situations.
stress concentration, fatigue,
endurance limit.
General Considerations in Machine
Design
 Use of Design Data Hand Book,
 Ergonomics of design-man-machine
 Present a video on Ergonomic
relationship, Design of controls -
and Aesthetic consideration
Design of equipment for control,
2 1 1,2 followed in Industries.
environment and safety.
 Discuss the case studies related
 Aesthetic consideration regarding
to Ergonomic and Aesthetic
shape, size, color and surface finish.
consideration in Design.
Design of display -Design of equipment
for Display.
Practice -
 Different screw thread
profiles - Metric, Acme, Square,
Design of Threaded Fasteners: Buttress, Knuckle, whit worth in
 Stresses in Screwed fasteners, bolts of sketch book/drawing sheet,
Uniform Strength.  Conventional representation of
 Initial tightening load – Tensile, threads.
Torsional shear stress, Shear stress Practice -
across thread, crushing stress, Bending  Draw the front and top view of
3 2 3,4
stress. ISO threaded Square &
 Stresses due to an external load Hexagonal bolt and Nut of 100
 Combined effect of initial tightening mm long* with a threaded
load and external load length of 50mm*. The diameter
 Leak Proof Joint and Joint separation of the bolt is 20 mm* across
 Numerical Examples. corner & side in Sketch book /
Drawing sheet.
 Create 3D model for the Square
and Hexagonal Bolt and Nut.
Design of Shafts: Practice –
 Type of shaft, shaft materials, Type of
4 2 3,4
loading on shaft, standard sizes of  Determine the Angle of twist by
shaft available using Torsion equipment.
Department of Technical Education, Government of Karnataka 99
  Shaft subjected to torsion only,
determination of shaft diameter
(hollow and solid shaft) on the basis
of Strength criterion, & Rigidity
criterion
 Numerical Examples.
Design of Shafts:
 Shaft subjected to bending only -
Determination of shaft diameter
Practice –
(hollow and solid shaft) subjected to
5 2 3,4 bending
 Determine the Angle of twist by
 Shaft subjected to combined torsion
using Torsion equipment.
& bending - Determination of shaft
diameter (hollow and solid shaft)
subjected to bending
Design of Keys & Couplings Practice -
 Types of key, materials of key,  Draw the Assembly of Muff
functions of key, Failure of key (by coupling for the designed values
Shearing and Crushing). in Drawing sheet.
6 2,3 3,4  Design of key (Determination of key  Prepare the 3D Model of the
dimension) Muff coupling using CAD
 Necessity of a coupling, advantages of software.
a coupling, types of couplings,  Develop the Muff coupling
 Design of muff coupling scaled model using 3D Printer.
Practice -
Design of Couplings-
7 2,3 3,4  Draw the Assembly of Flange
 Design of Flange coupling for the
coupling for the designed values
given power transmission.
in Drawing sheet.
Practice -
 Prepare the 3D Model of
Design of Couplings- Flange coupling for the
8 2,3  Design of Flange coupling for the designed values using CAD
given power transmission. software
 Develop the Flange coupling
scaled model using 3D Printer.
Practice –
 Draw the views of Knuckle
joint in Drawing sheet.
9 2,3 3,4
Design of Knuckle Joint  Prepare the 3D Model of the
 Design of Knuckle joint Knuckle joint for the designed
values using CAD software
 Develop the Knuckle Joint
scaled model using 3D Printer.
Basic Geometric Dimensioning and
Practice –(Refer Annexure - A –
 Tolerance symbols.
Suggestive only)
- Form controls– Straightness,
10 4 1,2 Flatness, Circularity, Cylindricity.
Understand and Practice the
- Profile controls – Profile of a line,
symbols used in Production
Profile of a surface
drawing.
- Orientation controls – Angularity,
Department of Technical Education, Government of Karnataka 10
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 Parallelism, Perpendicularity.
 Concept of limits, fits & allowances
 Representation of the following: (i)
Clearance fit (ii) Interference fit (iii)
Transition fit.
Basic Geometric Dimensioning and
 Tolerance symbols.
- Location controls – Practice –(Refer Annexure - A –
Position,Concentricity, Symmetry Suggestive only)
11 4 1,2 - Runout controls – Circular runout, Understand and Practice the
Total runout symbols used in Production
 Surface Finish symbols. drawing
 Production drawing
Need, Elements of Production drawing
Assembly drawings (Refer Annexure - B – Suggestive only)–Draw the
Assembled views of any one components in drawing sheet. Prepare 3D parts
and assemble by using CAD software.
12 4 4
 Engine Stuffing box of a steam engine
 C- Clamp
 Spring loaded relief valve
Assembly drawings (Refer Appendix - B – Suggestive Only)– Draw the
Assembled views of any one components in drawing sheet. Prepare 3D parts
and assemble by using CAD software.
13 4 4
 Screw Jack
 V-Block with clamp
 Cross Head

4. References:

Sl.
Author Title of Books Publication/Year
No.
Machine Design: An Pearson Education India, 5th
1. Robert L. Norton
Integrated Approach Edition, 2013
A Text book of Machine
2. R.S. Khurmi&[Link] S. Chand publication
Design
McGraw Hill Education
3. S G Kulkarni Machine Design
Publications
Introduction to Machine McGraw Hill Education
4. V B Bhandari
design Publications
K Mahadevan& K Design Data Hand Book for
5. CBS publications
Balaveera Reddy Mechanical Engineers
Dr K L Narayana, Dr P New Age International
6. Machine Design and Drawing
Anaiah,, K Venkareddy Limited, 3 Edition
rd

Technical Drawing with

7. Frederick Giesecke Peachpit Press, 15th Edition
Engineering Graphics
8. N D Bhatt Machine Drawing Charotar Publication, 2023

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5. CIE Assessment Methodologies

Duration Max
[Link] CIE Assessment Test Week (minutes) marks
1. CIE-1 Theory Test 4 90 50
2. CIE-2 Practice Test 7 180 50 Average of all
3 CIE-3 Theory Test 10 90 50 CIE=50
4. CIE-4 Practice Test 13 180 50 Marks
CIE-5 Portfolio evaluation of
5. all practices and through 1-13 50
Rubrics
Total 53 Marks

6. SEE - Theory Assessment Methodologies

Duration Max Min marks to

[Link] SEE – Theory Assessment
(minutes) marks pass
1. Semester End Examination-Theory 90 50 20

7. CIE Theory Test model question paper

Program Mechanical Engineering Semester- 4

Course Name Product Design, Drawing and Development Test I
Course Code 25ME41I Duration- 90 min Marks-50
Name of the Course Coordinator:
Note: Answer any one full question from each section. Each question carries equal marks.
Q. No Questions CL CO Marks
Section - 1
j) Apply the six stages of the new product development to a Passenger Car
design. What insights did you gain at each stage?
k) Identify which product life-cycle stage, is the most important? which stage
is riskiest? which stage appears to hold the greatest profit potential? Be 5+5+5
1 certain to explain the thinking behind each of your answer. Apply CO1 +10 =
l) Identify and analyze at least three factors that could influence the factor of 25
safety in a mechanical design.
m) In designing a new automated assembly robot, how would you integrate
general considerations in machine design with adherence to BIS standards?
e) Discuss why the appearance of product is often a major factor in attracting
the customer.
f) Analyze a specific workplace setting of an assembly line. How would you
apply ergonomic principles to improve the man-machine relationship? What
5+5+5
changes would you suggest to enhance user comfort and efficiency?
2 Apply CO1 +10 =
g) Discuss how you would integrate aesthetic considerations with ergonomic
25
principles in the design of office furniture. What trade-offs might you
encounter, and how would you resolve them to create a product that is both
visually appealing and comfortable?
h) For designing a control panel for an industrial machine, what factors

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 would you consider when designing the layout and functionality of the
controls?
Section - 2
j) Discuss the factors that influence the selection of materials for shafts in a
high-performance automotive application. What materials would you
recommend, and what properties make them suitable for this application?
k) 12 M20 x 2.5C bolts are used to hold the cylinder head of a reciprocating air
compressor in position. The air pressure is 7 MPa and the cylinder bore
5+10+
diameter is 100 mm. A soft copper gasket with long bolts is used for sealing.
3 Apply CO2 10 =
If the tensile yield stress of the bolt material is 500 MPa find the suitability
25
of the bolt for the purpose. Check if the joint is leak proof and also if any
joint separation may occur.
l) A solid shaft needs to be designed for a maximum torsion of 150 N-m. Using
a strength criterion, calculate the required diameter of the shaft if the
allowable shear stress is 60 MPa.
j) Identify and describe the different types of shafts used in mechanical
systems. In what applications would each type be most suitable, and why?
k) In a steam engine the steam pressure is 2 MPa and the cylinder diameter is
250 mm. The contact surfaces of the head and cylinder are ground and no
packing is required. Choose a suitable bolt so that the joint is leak proof. 5+10+
4 Assume number of bolts to be used is 12. Apply CO2 10 =
l) An engineer is designing a hollow shaft that must maintain a maximum 25
angle of twist of 2 degrees under a torsional load of 300 Nm. If the length of
the shaft is 1 m and the shear modulus is 75 GPa, calculate the required
outer diameter of the shaft based on the rigidity criterion. Assume the inner
diameter is to be 20 mm.
Note for the Course coordinator: Each question may have two, three, four and five subdivisions. Optional
questions in each section carry the same weightage of marks, cognitive level and course outcomes.

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

8. CIE Practice Test model question paper

Program Mechanical Engineering Semester 4

Course Name Product Design, Drawing and Development Test II
Course Code 25ME41I Duration 180 min Marks 50
Name of the Course Coordinator:
Note: Answer any one full question from the following
Questions CO Marks
`1. a) Draw and label the following screw thread profiles: Metric, Acme, Square,
Buttress and Whitworth. For each profile, discuss the typical applications where
they would be most effective.
b) Design a muff coupling which is used to connect two steel shafts transmitting 40 10+40
kW at 350 r.p.m. The material for the shafts and key is plain carbon steel for which 2&3 = 50
allowable shear and crushing stresses may be taken as 40 MPa and 80 MPa Marks
respectively. The material for the muff is cast iron for which the allowable shear
stress may be assumed as 15 MPa. Create the 3D model in CAD and Extract the
Principle views.
2. a) Draw the front and top view of ISO threaded Hexagonal bolt and Nut of 120 mm
long with a threaded length of 60mm. The diameter of the bolt is 25 mm across side. 10+40
Create the 3D model in CAD and Extract the Principle views. 2&3 = 50
b) Design a Cast Iron unprotected type flange coupling to transmit 15kW at 800 Marks
rpm. The maximum torque may be assumed 1.35 times the mean torque. The
Department of Technical Education, Government of Karnataka 10
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 permissible shear stress for Shaft, bolt and key material is 40 MPa. The permissible
crushing stress for bolt and key material is 80 MPa. The shear stress for Hub and
flange is 12 MPa. Assume that material used for Shaft and Key is same. Create the 3D
model in CAD and Extract the Principle views.

Scheme of Evaluation
Q. No 1
a) Drawing and labelling = 1 x 5 = 5 Marks, CO3 5
Each application = 1 x 5 = 5 Marks. CO2 5
b) Design = 20 Marks, CO2 20
3D Modelling = 10 Marks, CO3 10
Extracting the views = 10 Marks CO3 10
Q. No 2
a) Drawing of front and side view = 5 + 5 = 10 Marks, CO3 10
b) Design = 20 Marks, CO2 20
3D Modelling = 10 Marks, CO3 10
Extracting the views = 10 Marks CO3 10

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

9. Suggestive Activities for Tutorials:

 The students shall do minimum of one suggested activities
 List is an Example and not inclusive of all possible activities of the course.
 Student and Faculty are encouraged to choose activities that are relevant to the topic.

[Link]. Suggestive Activities for Tutorials

01 Design the foundation bolts (Number & Diameter) used in Electrical pole installation.

02 Design a suitable Coupling for different motor ratings and different shaft materials.

03 Develop a product from Concept design to Prototyping (at least 4 products).

04 Write and execute the Python Program for design of shafts.

10. Rubrics for Assessment of Graded Exercises (Qualitative Assessment)

Need
Unsatisfactory Satisfactory Good Excellent
Sl. Improvement Student
Dimension
No. Score
(0-5) (6-10) (11-15) (16-20) (20-25)

Fully prepared
Lacks several Adequately Mostly
Not with all
important prepared but prepared
1 Preparation prepared necessary 20
materials or missing key with minor
at all materials and
tools items omissions
tools
Some Test or task
Major errors Minor errors
Execution/ inconsistencie performed
Task not affecting in execution,
2 Implement s or flawlessly with 20
executed results or but overall
ation inaccuracies precision and
functionality effective
present accuracy
Quality of No quality Poor quality, Acceptable Good quality High-quality
3 15
Work demonstra major flaws quality with with minor output, meets or
Department of Technical Education, Government of Karnataka 10
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 ted impacting noticeable flaws exceeds
functionality defects standards
Mastery of tools
Use of No proper Weak use of Good use of
Basic use of and techniques
Tools/ tool use tools, tools, minor
4 tools, some demonstrated 20
Technique demonstra significant issues with
inefficiencies safely and
s ted risks noted technique
effectively
Most All required
Practical Major Major sections
Some sections sections are sections are
Record sections are missing or
5 are included, complete included and 25
submissio are not poorly
but lack detail. with minor thoroughly
n addressed. addressed.
omissions. detailed.
Average Marks=(20+20+15+20+25)/5=20 20
Note: Dimension and Descriptor shall be defined by the respective course coordinator as per the activities

11. SEE–Model Theory Question Paper

Program Mechanical Engineering Semester 4

Course Name Product Design, Drawing and Development Marks 50
90
Course Code 25ME41I Duration
Min
Note: Answer any one full question. Each full question carries equal marks.
Cognitive Course
Q No Questions Levels Outcomes Marks
Section -1
i. Design a Cast Iron unprotected type flange coupling to
transmit 200kW at 400 rpm. The permissible shear stress in
the shaft is 60 MPa & angle of twist is not to exceed 10 in a
length of 20 diameters. The allowable shear stress for the
CO2 25
hub and flange is 14MPa and for the bolt material is 40MPa.
Assume that maximum torque is 20% more than mean
1 Apply
torque. The Shearing and Crushing stress for the key is
60MPa and 130 MPa. Take G=84GPa.

ii. Draw the detailed engineering drawing of the Flange

CO3 25
coupling for the designed values. Include all necessary views
(top, side, section), dimensions, tolerances, and annotations.

i. Design a knuckle joint for a tie rod of a circular

section to sustain a maximum pull of 70 kN. The ultimate
strength of the material of the rod against tearing is 420
MPa. The ultimate tensile and shearing strength of the pin
CO2 25
material are 510 MPa and 396 MPa respectively.
Determine the tie rod section and pin section. Take factor
2 Apply
of safety = 6.

ii. Draw the detailed engineering drawing of the

Knuckle joint for the designed values. Include all necessary
CO3 25
views (top, side, section), dimensions, tolerances, and
annotations.

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13. Equipment/softwarelistwithSpecificationforabatchof30students

[Link]. Particulars Specification Quantity

01 Desk top computer Latest Configuration 20
02 Latest version of CAD software Any Licensed version 20

03 3-D Printing Machine PLA/ABS 3D printer 02

Annexure – A (Suggestive Only)

1. Production Drawing – Template Jig

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2. Production Drawing – Helical gear

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 Annexure– B (Suggestive Only)

1. Stuffing Box of a Steam Engine

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2. C - Clamp –

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3. Screw Jack –

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4. V-Block with Clamp –

5. Cross Head –

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6. Spring Loaded Relief Valve –

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 Government of Karnataka
DEPARTMENTOFTECHNICALEDUCATION

Program Mechanical Engineering Semester IV

Course Name Operations Management Type of Course Integrated
20ME42I 104hrs/
Course Code Contact Hours
Sem
Teaching Scheme L:T:P–4-0-4 Credits 6
CIE Marks 50 SEE Marks 50 (Theory)

1. Rationale: The syllabus is structured to progressively build the students' competencies from basic
concepts to advanced applications, ensuring they acquire a well-rounded understanding of
operations management. By integrating both theoretical knowledge and practical applications,
students are prepared to tackle real-world operational challenges effectively. This approach not only
enhances heir employ-ability but also equips them to drive efficiency, innovation, and strategic
decision-making within organizations.

The comprehensive coverage of topics ensures that students are versatile, capable of managing
diverse operations across different industries. The inclusion of modern tools and techniques ensures

that they are up-to-date with the latest developments in the field, preparing them for leadership

roles in operations management, supply chain management, and quality control.

2. Course Outcomes: At the end of the Course, the student will be able to:

Recognize basic concepts in Operations Management, including productivity and

CO-01
Decision making.
Apply planning, forecasting, and scheduling tools to optimize operational
CO-02 efficiency.
CO-03 Analyze layouts, inventory, and supply chain systems to enhance productivity.

CO-04 Perform work studies and time measurement to optimize processes.

Use quality tools and improvement methods like TQM and Six Sigma to enhance
CO-05 product and service quality.

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3. Details of Course Content

WEEK CO PO Theory Practice

Introduction to Operation  Visit an industry- Study the
Management manufacturing process and
 Meaning, Key Concepts, Importance, calculate the productivity of
Application the process using Labour
 Production Management vs. Operation and Machine Productivity
Management  Provide case study of the
1 1 1,2  Productivity- Concept, Types, Factors, Production System - Analyze
Strategies the system and identify key
 Competitiveness - Concept, Factors, elements that contribute to
Measure Competitiveness productivity and
 Relationship Between Productivity and competitiveness.
Competitiveness, simple numerical
problem
Process Planning  Create a practical route sheet
 Process Planning - Steps in Process for a specific component,
planning considering all necessary
 Process planning Techniques -Meaning, production aspects, tools,
Application in manufacturing , Benefits, and resources.
Challenges
a) Computer-Aided Process Planning  Develop an Operation Sheet
(CAPP) indicating Process Plan and
b) Group Technology (GT) Process flow chart for a
2 2 1,3
c) Cellular Manufacturing (CM), given component.
d) Simultaneous Engineering (SE),
e) Reverse Engineering (RE)
 Different Tools used in Process planning
 Purpose, Components, Challenges and
application
a) Route Sheets
b) Operation Sheets
 Make or Buy Decision- Concept, Factors,  Consider a scenario in a
Steps involved- Simple problems Mechanical Industry. Decide
 Outsourcing- Factors for Outsourcing , whether to make a product
Risks or buy a product
 Production types –Batch, Mass,Job
3 1 1,2
order- Applications-Factors  Virtual Tour on Batch, Mass
InfluencingProduction type , Pro’s and and continuous Process
Con’s
 Plant Location-Factors Influencing Plant
Location

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 Plant Layout  Preparing plant layout of
 Types, Principles of a Good Plant Layout college machine shop
 Techniques for Improving Layout  Provide a scenario to
Demand Forecasting Analyze Trend Cycle
4 2 1,4  Demand Forecasting
 Demand Behavior-Trend Cycle,
Seasonal Background
 Steps in Forecasting Process
 Methods of Forecasting

Forecasting tools  Provide a scenario to

 Qualitative approach- Delphi method, forecast demand by Delphi
5 2 2,3 Market Research method- Simple method and Market
Problems Research method

 Quantitative approach – Moving average  Provide a scenario to

method, Exponential smoothing method forecast demand by Moving
- Simple Problems average method
6 2 2,3  Provide a scenario to
forecast demand by
Exponential smoothing
Scheduling and Sequencingg  Provide a scenario for job
 Scheduling: Types, Timing of operations sequencing
to optimize production flow  Problems on practical
 Sequencing - Types, techniques to examples using CPM.
7 2,4 1,3
manage production order
 Introduction to Critical Path Method
(CPM) for efficient scheduling- Simple
Problems on practical examples
Work Study and Time Management
 Work Study and its importance in  Develop single handed
productivity improvement process chart with
 Method Study: Analyzing tasks for appropriate symbols
8 4 1,4 Develop two handed process
efficiency 

 Tools - Process Chart, Single handed and chart with appropriate

two Handed Process Chart - Simple symbol
Problems
 Man-machine chart – Simple problems  Provide a scenario and
 Assignment problems – Simple analyse Man-machine
problems activity for a given simple
 Work Measurement: Time study and process
setting standard times- Simple Problems
 Applications of Time Allowances: Rest,  Provide a scenario and
personal, and process allowances analyse a simple production
9 4 1,4
assignment problem

 Provide a scenario and

analyse Time Study in a
Practical Setting- calculate
the standard time for the
task and suggest
Department of Technical Education, Government of Karnataka 11
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 improvements.

Inventory Management
 Inventory Management- Objectives and Problems on
Functions of Inventory management  ABC Classification
 Various inventory Costs System of items
 Key terms: Demand, Minimum Stock
10 3 1,3 Level, Lead Time, Reorder time, Reorder  Economic Order
Level Quantity(for Fixed order
 Inventory Classification: ABC Analysis- quantity system/ Model 1)
Problems
 Economic Order Quantity (EOQ) -
Simple Problems
Supply Chain Management (SCM) Case study onInformation
 Introduction to SCM: Importance in Technology-
production and delivery  Bar Codes

 Components of SCM: Sourcing,  Radio Frequency

procurement, logistics, and distribution Identification
11 3 2,5
 Supply Chain Strategies: Just In Time
(JIT) and Lean Manufacturing
 Information Technology: Bar Codes,
Radio Frequency Identification

Quality Management
 Quality from The Customer’s  Provide a scenario and
Perspective analyse the problem using
 Quality from The Producer’s Perspective quality tools and interpret
 Cost of Quality- Cost of Achieving Good the results
Quality- Cost of Poor Quality- Quality
12 5 1,3
Productivity Ratio
 Quality Tools - Process Flowcharts, 5
Whys, Cause and Effect Diagrams, Check
sheets, Histograms, Pareto Analysis,
Scatter Diagrams

 TQM and QMS, Quality Management -

Customers Simple Practice problems on
 Quality Management in Supply Chain
 The Role of Employees in Quality  Kaizen,
Improvement  Quality Circles
13 5 1,3
 Kaizen – Continuous Improvement  Deming Wheel (PDCACycle)
 Quality Circles
 Process Improvement Team
 Six Sigma
 Breakthrough Strategy: DMAIC

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4. References:

Sl No Author Title of Books Publication/Year

1 Heizer, Jay "Operations Management" Pearson, 2021
McGraw-Hill,
2 Stevenson, W.J. "Operations Management"
2020
Chase, R.B., Jacobs, F.R., & "Operations Management for McGraw-Hill,
3
Aquilano, N.J. Competitive Advantage" 2021
Slack, N., Chambers, S., & Johnston,
4 "Operations Management" Pearson, 2020
R.
"Modern
5 Buffa, E.S., & Sarin, R.K. Production/Operations Wiley, 2020
Management"
"Operations Management: An
6 Hill, T. Palgrave, 2019
Integrated Approach"
7 Mahadevan, B. "Operations Management" Pearson, 2019
"Operations Management:
8 Russell, R.S., & Taylor, B.W. Creating Value along the Supply Wiley, 2020
Chain"
"Sustainable Operations
9 Baines, T., & Lightfoot, H. Routledge, 2019
Management"

"Supply Chain Management: An

10 Waters, D. Palgrave, 2020
Introduction to Logistics"

"World Class Manufacturing:

11 Schonberger, R.J. Free Press, 2020
The Next Decade"
"Cost Accounting: Foundations
12 Foster, S.T. Pearson, 2019
and Evolutions"

5 CIE Assessment Methodologies

Sl. Test Duration Max

CIE Assessment
No Week (minutes) Marks
1. CIE-1TheoryTest 4 90 50

2. CIE-2PracticeTest 7 180 50
Average of all
3. CIE-3TheoryTest 10 90 50 CIE=50Marks
4. CIE-4PracticeTest 13 180 50

CIE-5 Portfolio evaluation–all practices

5 and Activities through Rubrics 1-13 50

Total 50 Marks

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 6 SEE-Theory Assessment Methodologies

Sl. Duration Max Min Marks to

SEE–Theory Assessment
No (minutes) Marks Pass

1. Semester End Examination-Theory 90 50 20

7. CIE Theory Test model question paper

Program Mechanical Engineering Semester - IV

Course Name Operations Management Test I
Course Code 25ME42I Duration 90 min Marks 50
Name of the Course Coordinator:
Note: Answer any one full question from each section. Each full question carries equal marks.
Q. Cognitive Course
Questions Marks
No Level Outcome
Section - 1
F) A mechanical parts factory needs to allocate resources for
a high-demand product while managing other operations.
Compare how production management and operations Apply 01 10
management ensures balanced resource allocation across
the organization?
1 G) A manufacturing plant observes a consistent drop in
output due to machine downtime and inefficient workflows. Apply 01 05
Suggest strategies to enhance productivity
H) Discuss the risks involved in outsourcing a critical
component of a product. How would you ease these risks if Apply 01 05
the decision is to "buy"?
F) A manufacturing company, wants to improve its overall
productivity to meet increasing market demand and reduce
production costs. The company produces precision metal Apply 01 10
parts for the automotive industry. Identify the key factors
that affect productivity in the manufacturing process.
Discuss how each factor can influence overall productivity
2 G) Your factory produces machine parts, and demand often
fluctuates between large orders of standard parts and small Apply 01 05
orders of customized designs. What production type(s)
would best suit this situation, and why?
H) Your company needs a custom component for its new
product. What factors would you evaluate to decide whether Apply 01 05
to manufacture it in-house or outsource it?
Section – 2
A) A mechanical engineering company, "Precision Tech,"
3 manufactures the following products:

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 i) Custom-designed machine components for
specific clients.
ii) Standard bolts and nuts in large quantities.
iii) Specialized automotive parts for a limited series Apply 01 10
of vehicles.
Identify the most appropriate type of production for each of
the above case. Justify your selections by explaining how
each type of production aligns with factors like
customization, production volume, and cost-efficiency in the
mechanical sector.
B) A global automotive parts manufacturer, needs to
forecast the demand for a new car component—an advanced
braking system—to plan production schedules and inventory Apply 02 05
levels effectively. Identify the factors that should be
considered when forecasting the demand for the new
braking system.
C) A mid-sized automotive parts manufacturer, "Auto Gear
Solutions," specializes in producing custom gearbox
components for different car models. To improve efficiency
and reduce manual errors, the company decides to Apply 02 5
implement a Computer-Aided Process Planning (CAPP)
system. What are the likely challenges that the company has
to overcome?
A) A manufacturing company ,is in the process of
implementing a new product line. The company produces
precision-engineered components for the aerospace
industry and requires detailed operation sheets for each Apply 02 10.
part to ensure consistency and quality in production.
Describe the purpose of an operation sheet in a
manufacturing setting.
B) A manufacturing company ,specializes in reverse
engineering obsolete mechanical parts to refurbish and
4
maintain aging machinery for industrial plants. The
company often encounters challenges when attempting to Apply 02 05
replicate outdated or discontinued parts. Identify the
primary challenges the Industry faces during the reverse
engineering process
C) A company plans to manufacture a complex mechanical
part requiring high precision. Which tools would you Apply 02 05
recommend for effective process planning, and why?

Note for the Course coordinator: Each question may have one, two or three subdivisions. Optional
questions in each section carry the same weightage of marks, cognitive level and course outcomes.

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

Department of Technical Education, Government of Karnataka 11

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 8. CIE Practice Test model question paper

Program Mechanical Engineering Semester IV

Course Name Operations Management Test II

Course Code 25ME42I Duration 180 min Marks 50

Name of the Course Coordinator:

Note: Answer any one question from each section. Each question carries 25 marks

Questions CO Marks
Section-I
1. Provide case study of the Production System - Analyze the system and
identify key elements that contribute to productivity and
competitiveness. Provide a detailed report. 01 25
2. P provide a scenario in a Mechanical Industry. Decide whether to make a
product or buy a product. Provide a detailed report.
Section-II

1. Provide a scenario. Forecast the demand by Delphi method

02 25
2. Provide a scenario to forecast demand by Exponential smoothing
Scheme of Assessment for Section I & II CO
a) Understanding of the System : 5 Marks
b) Analysis : 10 Marks
01 25
c) Factors Influencing : 5 Marks
d) Recommendations and Conclusions : 5 Marks
a) Understanding Forecast Demand: 5 Marks
b) Selection of Forecast Demand : 5 Marks
02 25
c) Applying Forecast Demand: 10 Marks
d) Evaluation of Forecast Accuracy: 5 Marks
Total Marks 50

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

9. Suggestive Activities for Tutorials:

 The students shall do minimum of one suggested activities

 List is an Example and not inclusive of all possible activities of the course.
 Student and Faculty are encouraged to choose activities that are relevant to the topic.

Sl.
No. Suggestive Activities for Tutorials
A mechanical manufacturer using batch production for shafts and bearings notices
01 frequent downtime due to retooling between batches. Propose solutions to minimize

Department of Technical Education, Government of Karnataka 12

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 production delays.

02 Employees in a mechanical assembly line lack the skills needed for operating advanced
equipment. Design a strategy to improve their productivity through training and
development programs.
A new product launch involves several unfamiliar manufacturing steps. How can tools
03 like failure mode and effects analysis (FMEA) or simulation models be used to
mitigate risks during process planning?
Compare the forecasted values to actual demand to evaluate the performance of
04 Exponential Smoothing. Discuss if the chosen smoothing constant (α) provided an
adequate balance between bias and responsiveness.
A company is evaluating its quality management practices and needs to understand
05 the cost implications associated with achieving good quality and poor [Link]
how understanding these costs can help the company make informed decisions about
its quality strategies and improvements.

10 Rubrics for Assessment of Graded Exercises (QualitativeAssessment)

Need

Student’s
Unsatisfactory Satisfactory Good Excellent
Sl. Improvement
Dimension

Score
No.
(0-5) (6-10) (11-15) (16-20) (20-25)

Fully
Lacks
Adequately Mostlypre
preparedwith
Not severalimport
preparedb paredwith
1 Preparation allnecessaryma 20
prepared antmaterials
ut minoromis
terialsand
atall ortools
missingkey sions tools
items
Someincon Minorerro Taskperformed
Execution/Im Major sistencies rs flawlessly
Task
2 plementation errorsaffectingr orinaccura inexecutio withprecisiona 20
notexecu
esults cie n,butovera nd
ted
s present ll accuracy
effective
Poor Acceptable High-
No quality,major Goodqu qualityoutput
Quality quality
3 qualitydemo flaws ality 15
ofWork withnoticea
nstrated withminorfl
ble
defects aws
Mastery of
No Basic use
Good use toolsand
Weak use
Use of propertool oftools,
oftools, techniquesdem
4 oftools, 20
Tools/Tech usedemonstr somein
minorissue onstrated
significantrisks
niques ated efficiencys
s
noted
withtechniq
ue
Somesectio Mostsectio All
Majorsection Major
PracticalRe ns ns requiredsect
s sectionsare
5 cordsubmi areincluded arecomplet ions 25
arenotaddre missing
ssion ,butlack ewithminor areincluded
ssed. orpoorlyaddr
detail. omissions. andthoroug
essed.
hly
detailed.

Department of Technical Education, Government of Karnataka 12

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 Average Marks=(20+20+15+20+25)/5=20

Note:DimensionandDescriptorshallbedefinedbytherespectivecoursecoordinatoraspertheactivities

12 SEE–Model Theory Question Paper

Program Mechanical Engineering Semester IV

Course Name Operations Management Marks 50
Course Code 25ME42I Duration 90 Min
Note: Answer any one full question from each section. Each full question carries equal marks.
Cognitive
Q No Questions CO Marks
Levels
Section -1
a) Imagine you are the operations manager of a manufacturing
company experiencing delays in product delivery due to
inefficiencies in the production process. Highlight the
importance effective operations management to resolve these
issues.
1 b) As a production manager in a mechanical manufacturing Apply CO1 5+5=10
company, you need to choose the right production type—Job,
Batch, or Mass—for the following project: Producing a limited
series of high-precision parts for aerospace. Explain which
production type you would select for this project and why?
a) You are a plant manager in a manufacturing company,
tasked with improving productivity. Explain how you would
approach improving each type of productivity?
b) A project manager for a manufacturing firm, need to select
2 the location for a new plant. One potential site is in a Apply CO1 5+5=10
developing industrial park near a major metropolitan area,
offering access to a skilled workforce, good infrastructure, and
proximity to key suppliers and customers. Discuss the factors
considered in selecting this site.
Section -2
a) A team is tasked with integrating Computer-Aided Process
Planning (CAPP) into a manufacturing facility. During the
implementation phase, several challenges are [Link]
specific challenges would you expect to face during this
3 Apply CO2 5+5=10
process?
b) A company is using the Delphi method to forecast the cost
of a new manufacturing process. The panel of experts provides
the following estimates (in thousands of dollars):Expert 1:
Department of Technical Education, Government of Karnataka 12
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 $120,000,Expert 2: $150,000, Expert 3: $140,000, Expert 4:
$160,000, Expert 5: $130,000. Calculate the Delphi method
forecast for the cost.
a) A company is planning to set up a new manufacturing
facility to produce automotive components. The available
space is limited, and the plant layout needs to accommodate
multiple processes such as assembly, machining, and quality
control. How would you utilize techniques to optimize the
layout?
4 Apply CO2 5+5=10
b) A company conducted a survey to understand customer
preferences for a new product. The results showed the
following preferences:200 people preferred Product A, 300
people preferred Product B, 100 people preferred Product C.
Calculate the market share for each product, assuming a total
of 600 responses.
Section -3
a) A workshop uses the following tools. Perform an ABC
analysis based on their annual usage cost.
Tool Annual Usage Unit Cost
Name (Units) ($)
Wrench 800 2
Hammer 400 5
Drill Bit 300 10
Grinder 50 200
5 Lathe Tool 20 500 Apply CO3 8+2=10
Saw Blade 100 50

b) In mechanical parts store, a customer needs a specific

bolt. The staff uses a bar code scanner to identify the bolt's
details and check its availability in the system. Explain how
the barcode system benefits both the customer and the staff in
this scenario?
a) A mechanical company uses 10,000 bearings per year. The
ordering cost is ₹ 500 per order, and the holding cost is ₹ 2
per bearing per year. Determine the EOQ, total inventory cost
if the unit price of a bearing is ₹ 10 and number of orders
placed per year. Apply CO3 8+2=10
6 b) A mechanical assembly line produces car engines. The
company notices excessive storage costs due to a surplus of
unused parts in their warehouse. How can implementing JIT
address this issue?

Section -4
a) Small mechanical assembly line have workers assembling
small gears into gearboxes. Each assembly involves picking up Apply CO4 5+5=10
7
the gear from a bin, aligning it into the gearbox, and then
Department of Technical Education, Government of Karnataka 12
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 returning to the starting point for the next gear. Identify the
unnecessary movements that a worker is making during this
assembly process and suggest ways to streamline it using a 2-
handed process chart.
b) Determining the Critical Path. A project consists of the
following activities and duration:

Activity Predecessor(s) Duration (days)

A None 3
B A 2
C A 4
D B, C 2
a) A worker is observed performing a task multiple times, and
the following data is recorded. Calculating Standard Time
Cycle Time
Observation
(minutes)
1 5.2
2 5.5
8 3 5.3 Apply CO4 5+5=10
4 5.4
b) A company manufacturing machine parts observes that
workers spend considerable time walking between the storage
area and the assembly workstation. This delays the overall
production process. How can method study help address this
issue?
Section -5
a) Recurring issues with misalignment in the assembly of
heavy mechanical parts, which results in increased rejection
rates are encountered. Despite re-adjusting machinery and
retraining staff, the problem [Link] the application
of 5 Whys for troubleshooting a recurring issue in the
9 assembly process of mechanical components. Apply CO5 5+5=10
b) A recurring bottleneck is identified in the assembly line of a
manufacturing process. Despite previous efforts to improve
efficiency, the issue persists. How would you apply the Kaizen
philosophy to address this bottleneck?

a) In a manufacturing plant an increase in defects, such as

misalignments in components, wrong part placements, and
surface scratches on the final product are observed. Describe
how you would use a Pareto Chart to identify the most
10 Apply CO5 5+5=10
common defects in a production process.
b) A new product launch has been delayed due to quality
issues related to manufacturing defects. Management wants
to avoid similar issues in the future and has asked to apply Six

Department of Technical Education, Government of Karnataka 12

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 Sigma methodologies to the process. How would you apply Six
Sigma principles to improve the manufacturing process and
prevent similar delays in future product launches?

Department of Technical Education, Government of Karnataka 12

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 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION

Program MECHANICAL ENGG. Semester IV

Machine Tool Technology and
Course Name Type of Course Integrated
CNC Programming
Course Code 25ME43I Contact Hours 91Hrs/Sem
Teaching Scheme L: T:P [Link] Credits 5
CIE Marks 50 SEE Marks 50 (Practice)

1. Rationale: Diploma Engineers are responsible for supervising production processes

to achieve production targets and for optimal utilization of resources. It is also
essential to produce parts with high precision and accuracy in less time to achieve
market goals. For this purpose, knowledge about various machining processes is
required to be imparted. The students are to be trained and equipped with adequate
theoretical and practical skills about Metal Cutting Phenomenon and various
processes like turning, millingusing conventional and CNC tooling. Hence, this course
is introduced to provide hands on experience on various conventional machine tools
and to develop skills required for programming, tooling for CNC machine.

2. Course Outcomes: At the end of the Course, the student will be able to:

CO-01 Practice the safety standards in machine shop.

CO-02 Perform lathe and milling operations

CO-03
Prepare process plan, estimate production cost as per given drawing for lathe and milling
operations.
Develop CNC turning and milling part programs for given production drawing and
CO-04
simulate/prepare the model.

3. Course Content

WEEK CO PO Theory Practice

Theory of Metal Cutting
 Material Removal Process - Introduction, Classification, Mechanics of
Metal Cutting
 Types of Chips, Orthogonal & Oblique Cutting
1 1 1
 Cutting Tool - Geometry of Single Point Cutting Tool, Cutting Tool Material
- Selection, Cutting Fluids - Functions, Types, Properties
 Safety Standards practiced in machine shop
o Do’s and Don’ts
Department of Technical Education, Government of Karnataka 12
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 o Safety signs, Protection - PPE(Personnel Protective Equipment), Fire
protection, Electrical & Chemical safety.
o First aid
o Machine shop layout
Turning
 Lathe - Introduction, Classification.
 Demonstrate the various parts of lathe and their functions.
 Explain the Lathe Terminologies - Feed, Speed, Depth of cut & Machining
2 2,3 1,2,4 time
 Demonstrate lathe Operations- facing, plain turning, step turning, taper
turning (compound rest method), chamfering, knurling, grooving and
threading operations (external)
 Inspection - demonstration on checking & documenting the dimensions
and surface finish using various measuring tools
 Preparation of Process planning sheet for lathe - include component
drawing, process list, machine used, tool selection, cutting parameters
and selection of measuring tools for inspection
 Estimation - Material costs, Labour costs, Overhead Costs, Machining
3 2,3 1,2
Time & Cost, Total Cost, Selling price & Cost of Scrap
 Estimation of production cost for lathe operations
 Preventive Maintenance of Lathe - Inspection, Replace/Repairs, Cleaning,
Lubrication
Students shall (as given in Annexure-A)
 Prepare the process plan for the given component drawing
1,2,4
4 2,3  Estimate its production cost.
,7
 Prepare the model in lathe machine
 Document dimensional checks.
Milling
 Milling - Introduction, Classification, Up milling & Down milling process
 Explain Milling terminologies - Feed, Speed, Depth of cut & Machining
time
 Demonstrate various parts of milling machine with their functions.
5 2,3 1,2,4  Demonstrate Indexing - Index Head Parts, Methods of Indexing, Direct and
Simple Indexing
 Milling practice –demonstration on milling model incorporating facing
and cutting operations
 Inspection - Concepts and demonstration on checking & documenting
dimensions and surface finish using various measuring tools
 Preparation of Process plan for milling - include component drawing,
process list, machine used, tool selection, cutting parameters and
selection of measuring tools for inspection
6 2,3 1,2
 Estimation of production cost for milling(cutting/facing)operations
 Preventive Maintenance of Milling Machine- Inspection, Replace/Repairs,
Cleaning, Lubrication
Students shall (as given in Annexure-B)
 Prepare the process plan for the given component drawing
1,2,4
7 2,3  Estimate its production cost.
,7
 Prepare the model in milling machine
 Document dimensional checks

Department of Technical Education, Government of Karnataka 12

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 CNC Machines
 Introduction, Advantages of CNC machines over conventional machines
 Safety standards practiced in CNC machine shop
 Illustrate various parts of CNC Turning & Milling machine with their
8 4 1 functions.
 Axis convention of CNC machines, Machine Zero & Work Zero
 Compensation - Tool Length, Nose Radius, Wear & Offset Compensation
 Work/Tool setting, Tool Offset, Tool Wear Offset, Modes
(JOG/Edit/MDI/Single Block/Auto) in CNC Turning & Milling machine
CNC Programming
 CNC Programming sequence & Format, Absolute and Incremental system
9 4 1,2,4  G Codes, M codes, Feed, Speed, Depth of cut
 Develop CNC turning program and simulate/prepare the model –
Illustration and Practice as given in Annexure-C
10 4 1,2,4  Develop CNC milling program and simulate/prepare the model –
Illustration and Practice as given in Annexure-D
 Canned cycles (CNC Turning Center) - G70, G71, G72, G75, G76
11 4 1,2,4  Develop CNC turning program using canned cycles and simulate/prepare
the model – Illustration and Practice
 Canned Cycles (CNC Milling Center) - G80, G81, G82, G83, G84
12 4 1,2,4  Develop CNC milling program using canned cycles and simulate/prepare
the model – Illustration and Practice
 Mirroring & Subroutines
13 4 1,2,4  Develop CNC turning/milling program for mirroring with subroutines and
simulate/prepare the model – Illustration and Practice

4. References

Sl. Author Title of Books Publication/Year

No.
1. [Link] Manufacturing Technology - Vol II Mc Graw Hill, 2018
2. Serope Kalpakjian Manufacturing Engineering and Pearson, 2021
Steven R. Schmid Technology
3. [Link] Mechanical Estimation and Costing Khanna Publishers, 2001
[Link]
4. [Link] Process Planning and Cost Estimation New Age International
Publishers, 2015
5. [Link] Process Planning and Cost Estimation New Age International
[Link] Publishers, 2017
[Link] Ramnath
6. [Link] CAD/CAM Principles and Applications Mc Graw Hill, 2017
7. Mikell P. Groover Automation, Production Systems and Pearson, 2024
Computer Aided Manufacturing
8. [Link] Computer Numerical Control, Machines New Academic Science, 2018
and Computed Aided Manufacture

5. CIE Assessment Methodologies

Department of Technical Education, Government of Karnataka 12
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 Test Duration Max
[Link] CIE Assessment
Week (minutes) Marks
1. CIE-1TheoryTest 4 90 50

2. CIE-2Practice Test 7 180 50 Average

of all
3 CIE-3TheoryTest 10 90 50 CIE=50
Marks
4. CIE-4Practice Test 13 180 50

CIE-5 Portfolio of all the practices and activities through

-
5 Rubrics 1-13 50
Total 50 Marks

6. SEE – Practice Assessment Methodologies

Duration
[Link] SEE – Practice Assessment Max. Marks Min. Marks to Pass
(minutes)
1. Semester End Examination-Practice 180 50 20

7. CIE Theory Test model question paper

Program Mechanical Engineering Semester -IV
Course Name Machine Tool Technology & CNC Programming Test I/III
Course Code 25ME43I Duration 90 min Marks 50
Name of the Course Coordinator:
Note: Answer any one full question from each section. Each full question carries equal marks.
Cognitive Course
[Link] Questions Marks
Level Outcome
Section - 1
a) Select appropriate cutting tool material for machining cast iron work piece. Apply 1 5X5
Justify. =
b) Select appropriate cutting method whether oblique or orthogonal for turning Apply 1 25
operation and describe the observations made during the operation.
c)Discontinuous chips were produced while machining operation, list the Apply 1
probable causes and corrections
1
d) Make use of the sketch to explain the process of creating patterned/grip Apply 1
surface on the cylindrical component.
e)Identify the cutting forces produced during Apply 1
i. tapping operation
ii. threading operation
a)Select appropriate cutting fluid used while machining HSS workpiece. Justify. Apply 1
b)Select appropriate cutting method whether oblique or orthogonal for thread Apply 1
cutting operation and describe the observations made during the operation.
c)Identify the chips formed for following cases Apply 1
o Brittle material
o Ductile material
2
o Titanium
o Severe work hardened material
o Metals with low thermal conductivity
d)Make use of the sketch to explain the process of creating tapered surfaces on Apply 1
cylindrical component.
Department of Technical Education, Government of Karnataka 12
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 e)Make use of the sketch to explain the process of creating helix on cylindrical Apply 1
component for fastening purposes.
Section - 2
a)Prepare the process planning sheet for the given component drawing. Apply 3 10+15
Assume missing data suitably. All dimensions in mm. =
25
3mmpitch

O 40 O 30 O 25

40
20 30 50

3 b)Estimate the cost of material of component made of C.I shown in figure

below, if C.I weight 7.7 gm/cm3 and material cost is Rs. 60/kg. All dimensions Apply 3
in mm.
6 25 6 75

O 50
O 30

O 30
30°

a)A product is manufactured on lathe machine, determine the selling price of Apply 3
the product for the following conditions.
o Material cost = Rs. 700
o Labour cost for Cutting and setting up = Rs. 150
o Labour cost for turning, threading = Rs. 160
o Machining time = 2.5 hours
o Machining cost for Turning, threading = Rs. 50/hour
o Cost of tools = Rs. 100
o Over head cost = 150% of total labour cost
o Profit = 20% of selling price
b)A rod of 30mm dia. 100mm long is to be machined on a lathe to make Apply 3
4
component as shown in figure. Calculate the machining cost. Take Cutting
speed is 30m/min for turning/knurling and 10m/min for threading, feed as
3mm/rev. for turning/knurling and 1mm/rev. for threading. Depth of cut being
2.5 mm. All dimensions in mm.
3 mmpitch
O 25

O 25
O 10

30 15 50
Note for the Course coordinator: Each question may have one, two or three subdivisions. Optional questions
in each section carry the same weightage of marks, cognitive level and course outcomes.

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

Department of Technical Education, Government of Karnataka 13

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 8. CIE Practice Test model question paper

Program Mechanical Engineering Semester IV

Course Name Machine Tool Technology & CNC Programming Test II
Course Code 20ME43I Duration 180 min Marks 50
Name of the Course Coordinator:
Questions CO Marks
1. Question on Lathe(Turning) Operations with process plan and determination of 2,3 50
production cost of the product for given parameters
{ Prepare the given model in lathe machine, with process plan and estimate the
cost of production. Raw Material size = Material Cost = Rs. 55/kg.
Density of raw material = 7.8 gm./cc. Labour Cost = 200% of Material Cost. For
turning, Cutting speed = 40 m/min., Feed = 0.4 mm/rev., Depth of cut = 2.5
mm/per pass and for Threading, cutting speed = 8 m/min. Machining Cost = Rs.
100/hr. Overhead charges = 20% of Material Cost. Consider missing data suitably.
1 x 45v M25

O 30 O 25 O 25 O 20
O 20 O 25

20 20 10 10 20 5 20
105
All dimensions are in mm }

OR

Question on Milling Operations with process plan and determination of

production cost of the product for given parameters
{ Mill Keyways on cylinder surface of Φ30 mm for length 30mm as per given
sketch, with process plan and estimate the cost of production. The width and
depth of keyway is 5 mm and 4 mm respectively. Raw Material Cost = Rs.
11/piece. Density of raw material = 7.9 gm./cc. Cost of Scrap = Rs. 20/kg. Labour
Cost = Rs. 100/hour. For milling, Feed = 30 mm/min., Depth of cut = 1 mm/per
cut. Overall setup and indexing time = 15 mins. Machining Cost = Rs. 200/hr.
Overhead charges = 25% of Material Cost. Consider suitable missing data.
30 O 30

All Dimensions are in mm}

Scheme of assessment
a. Process planning sheet = 10 Marks 3
b. Estimation of Production Cost = 10 Marks 3
c. Performing Operations on Machine = 25 Marks 2
d. Dimensional accuracy = 05 Marks 2
Department of Technical Education, Government of Karnataka 13
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 Total Marks 50

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

Program Mechanical Engineering Semester IV

CourseName Machine Tool Technology & CNC Programming Test IV
CourseCode 20ME43I Duration 180 min Marks 50
Name of the Course Coordinator:
Questions CO Marks
1. Question on writing CNC program for Turning model, Simulation / Preparation 4 50
of model on CNC Machine
{ Develop a part program for circular interpolation utilize canned cycles
and simulate/prepare. Blank size Φ42 mm x 152 mm.
150
75
10

O 40

R 12 R 10
R 10

All dimensions are in mm}

2. Question on writing CNC program for Milling model, Simulation / Preparation

of model on CNC Machine
{ Develop CNC Milling part program for drilling using canned cycles and
simulate / prepare. Blank size 100mm x 100mm x 20mm. Hole depth 10 mm.

Department of Technical Education, Government of Karnataka 13

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 10
20
20
O10 x 4 holes

O 20
100

30
20
20 30 20
100
All Dimensions are in mm }

Scheme of assessment
a. Writing CNC program for Turning model = 15 Marks 4
b. Writing CNC program for Milling model = 15 Marks 4
c. Simulation/Preparation of model on CNC machine (Any 1) = 20 Marks 4
Total Marks 50

9. Suggestive Activities for Tutorials (Any 6):

 The students shall do minimum of one suggested activities

 List is an Example and not inclusive of all possible activities of the course.
 Student and Faculty are encouraged to choose activities that are relevant to the topic.

Sl.
No. Suggestive Activities for Tutorials
1 Prepare the given lathe dead center in Lathe machine. Flat end has countersink hole of dia. 4mm,
depth 8mm and countersink dia. 6mm. Make a survey and collect the required missing data.
Also,
 Prepare Process Plan
 Estimate Cost of Production
 Document Dimensional Checks
 Prepare the CNC part program
 Simulate/Prepare the model in CNC Lathe with different material.

Department of Technical Education, Government of Karnataka 13

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 4

O 24
60° O 18 O 20

78,8
130
All dimensions are in mm.
2 Prepare the given Tommy Bar of Screw Jack in Lathe machine. Make a survey and collect the required
missing data.
Also,
 Prepare Process Plan
 Estimate Cost of Production
 Document Dimensional Checks
 Prepare the CNC part program (except knurling)
 Simulate/Prepare the model in CNC Lathe with different material.
45°
O 12

O 20
62 100
275
All dimensions are in mm.
3 Prepare the given Plug Gauge in Lathe machine. Make a survey and collect the required
missing data.
Also,
 Prepare Process Plan
 Estimate Cost of Production
 Document Dimensional Checks
 Prepare the CNC part program (except knurling)
 Simulate/Prepare the model in CNC Lathe with different material.

O 20 O 15 O 20.2

O 32 O 19
O 111
All dimensions are in mm.
4 Prepare ¾” Square head pipe plug in lathe and milling machine, along with process plan,
estimation of production cost, documentation of dimensional checks, CNC part program.
Make a survey and collect the required missing data.
5 Carry out servicing of Lathe/Milling machine. Present and submit its report.
6. Make a presentation on influence of coolant in CNC by explaining purpose, delivery methods
of coolants, types of coolants, properties of coolants, health and safety issues, recycling and
Department of Technical Education, Government of Karnataka 13
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 disposal of cutting lubricants. Also submit the report.
7. Prepare M25 Bolt and Nut along with process plan, estimation of production cost,
documentation of dimensional checks, CNC part program. Make a survey and collect the
required missing data.
8. Collect Manufacturers Catalog of Lathe/Milling/CNC machine and select the model required
for the particular application. Present and submit the report on selection criteria adopted.
9. Visit nearby Industries/Workshops having special purpose lathe/milling machines. Study its
features and applications. Present and submit its report.

10. Rubrics for Assessment of Activity(Qualitative Assessment)

Sl. Dimension Needs Basic Competent Proficient Excellent Students

No. Improvement Score
0-5 6-10 11-15 16-20 21-25

1 Survey and Not collected or Incomplete or Adequate but Mostly complete, Thoroughly 24
Data analyzed. poorly lacks with a clear collected &
Collection organized, with organization or structure, organized in a
little to no clarity in some though some effective manner,
analysis areas. data may be less with a well-
organized structured
analysis.
2 Operations / Not carried out Partially carried, Partially carried, Mostly carried Carefully 18
Task Carried properly leading to some but there is correctly, with followed, and is
significant noticeable minor mistakes executed with
errors disorganization high skill and
accuracy.
3 Impact and Fails to make anMinimal impact Moderate impact Positive impact Outstanding 6
Effectiveness impact or is and fall short of but could be effectively impact exceeding
of work/task ineffective in achieving its more effective achieving its expectations
achieving goals intended purpose
purpose
4 Presentation Missing critical Incomplete, Includes some Mostly complete, Comprehensive, 6
and Report information, poorly key elements but with minor well-organized,
submission incomplete, or organized, or lacks clarity or omissions or and includes all
unclear. lacks important detail in some organizational necessary
components. areas. issues. details.
Average Marks=(24+18+6+6)/4=13.5 14

Note: Dimension and Descriptor shall be defined by the respective course coordinator as per the activities

Department of Technical Education, Government of Karnataka 13

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 11. SEE- Model Practice Question Paper

Program DIPLOMA IN MECHANICAL ENGINEERING Semester IV

Course Name MACHINE TOOL TECHNOLOGY & CNC Course Code : 25ME43I Duration 180 min
PROGRAMMING
CO Marks
Questions
1. Question on Lathe(Turning) Operations with process plan and determination of 02,03 30
production cost of the product for given parameters (Minimum of 3 operations
including either threading or taper turning)
{ Prepare the given model in lathe machine, with process plan and estimate the
cost of production. Raw Material size = Material Cost = Rs. 55/kg.
Density of raw material = 7.8 gm./cc. Labour Cost = 200% of Material Cost. For
turning, Cutting speed = 40 m/min., Feed = 0.4 mm/rev., Depth of cut = 2.5
mm/per pass and for Threading, cutting speed = 8 m/min. Machining Cost = Rs.
100/hr. Overhead charges = 20% of Material Cost. Consider suitable missing data.
M10 x 1.5

O 25 O 20
O 15

10 20
8 20 30
All dimensions are in mm. }

OR

Question on Milling Operations with process plan and determination of

production cost of the product for given parameters
{ Mill Hexagon on cylinder surface of Φ30 mm for length 30mm as per given
sketch, with process plan and estimate the cost of production. Raw Material Cost =
Rs. 80/kg. Density of raw material = 8.0 gm./cc. Cost of Scrap = Rs. 20/kg. Labour
Cost = Rs. 70/hour. For milling, Speed = 200 r.p.m., Feed = 0.25 mm/rev. Overall
Setup and Indexing time = 21 mins. Machining Cost = Rs. 200/hr. Overhead
charges = 20% of Material Cost. Consider suitable missing data.
2 X 45 v

O 25

60 30 30 25
All dimensions are in mm }
Scheme of assessment
1. a. Process planning sheet = 10 Marks
b. Estimation of Production Cost = 10 Marks
c. Performing Operations on Machine = 25 Marks
d. Dimensional accuracy = 05 Marks
Total Marks 50

Department of Technical Education, Government of Karnataka 13

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 3) Signature of the Examiner 2) Signature of the Examiner

12. Equipment/Consumables/softwarelistwithSpecificationforabatchof30students
[Link]. Particulars Specification Quantity
01 Center Lathe with all accessories and Approximate 30
Swing Over bed : 450 mm
attachments (Gear Driven) Swing Over Carriage : 275 mm
Admit between Centers : 550 mm
Other Features Suitably Selected
02 Column and Knee type Vertical Milling machine Approximate 01
Table Size 250 x 850 mm
with all attachments Arbor Diameter - Φ20 - Φ28 mm
Other Features Suitably Selected
03 CNC Turning Centre (Tutor / Productive) Approximate 01
Turning Dia. : 100 mm
Turning Length : 300 mm
Turret head : 8 Stations
Automatic Tool Changer Feature
Controller : Fanuc
Other Features Suitably Selected
04 CNC Milling Centre (Tutor / Productive) Approximate 01
Working Size : 250 x250 mm
Working thickness : 50 mm
Automatic Tool Changer Feature
Controller : Fanuc
Other Features Suitably Selected
05 CNC Simulation Software Turning/Milling Environment 30 User
06 HSS Cutting Tool for turning Square tool 10 to 20 mm 30
Shank length 50 to 165 mm
07 Cemented Carbide tippled tools with holder For Turning operation 30
brazed
08 Knurling tool – Rough 2 No. of Knurls -Standard size 15
09 Knurling tool - Smooth 2 No. of Knurls -Standard size 15
10 Threading tool Standard 15
11 Vernier Calipers Measuring Range - 0 to 300 mm 30
12 Outer Calipers Measuring Range - 0 to 50 mm 30
13 Steel Scale Measuring Range - 0 to 300 mm 20
14 Dial gauge for setting work Graduation - 0.01 mm, Range - 10 15
mm
15 Counter sunk drill bit Dia - 6mm, Tapered shank 30
16 Marking divider Range - 200 mm 30
17 Marking punch Standard 30
18 Combination set square Standard 15
19 Surface plate Size of plate - 400 mm * 400 mm 01
20
21 Keyway / Slot cutter Keyway/Slot cutter set 01
Outer Diameter range - 20to200mm
Thickness range - 0.5 to 10 mm
22 Gear cutter (Spur teeth) Set of standard sizes 01
23 Concave Milling cutter Set of Standard sizes 01
24 Convex milling cutter Set of Standard sizes 01
25 End milling cutter Set of Standard sizes 01
26 First Aid Kit Workshop Standard 01

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Annexure-A
Suggestive Model Drawings for Practice in lathe

Turning Models (All Dimensions are in mm)

3mmpitch

O 40 O 30 O 25

40
20 30 50

Figure 1

6 25 6 75

O 50
O 30

O 30
30°

Figure 2

3 mmpitch
O 25

O 25
O 10

30 15 50

Figure 3
M10 x 1.5

O 25 O 20
O 15

10 20
8 20 30
Figure 4

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 1 x 45v M25

O 30 O 25 O 25 O 20
O 20 O 25

20 20 10 10 20 5 20
105
Figure 5
Annexure-B

Suggestive Model Drawings for Practice in Milling machine

Hexagon Milling practice - Mill Hexagon on cylinder surface of Φ30 mm for length 30mm
2 X 45 v

O 25

60 30 30 25
All Dimensions are in mm
Key way cutting practice – Keyway width = 5mm & depth = 4mm

30 O 30

All Dimensions are in mm

Spur Gear cutting practice - Machine Spur Gear having 25 numbers of teeth and module
1.5 mm/tooth.

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Annexure-C

CNC Turning

Develop a part program for circular interpolation utilize canned cycles and simulate/prepare.
Blank size Φ42 mm x 152 mm. (Hint use tool radius compensation)
150
75
10

O 40

R 12 R 10
R 10
All dimensions are in mm

Develop a part program for thread cutting, grooving and simulate/prepare. Blank size Φ102 x
100 mm.
22.5 7.5 M30 x 2 7.5 22.5

O 25 O 20
O 30

120
All dimensions are in mm

Annexure-D

CNC Milling
Develop part program to mill the groove and Develop CNC Milling part program for circular
simulate/prepare. Blank size 100mm x 100mm and rectangular pocketing and simulate /
x 20mm. Groove depth 10 mm. prepare. Blank size 100mm x 100mm x 20mm.
Pocket depth 10 mm.

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 10
10

20
20

SECTIONA-A
15

10

0
R2
R5
15 10 15

100
100

50
A A

10
15

10 30 25
100 100
All Dimensions are in mm All Dimensions are in mm
Figure 4.1 Figure 4.2

Develop CNC Milling part program for drilling Develop CNC Milling part program for
using canned cycles and simulate / prepare. mirroring with subroutines and simulate /
Blank size 100mm x 100mm x 20mm. Hole prepare. Blank size 200mm x 200mm x 20mm.
depth 10 mm. Hole depth 10 mm.
10
10

20
20

35 30
20

O10 x 4 holes
30
O 20
35
200
100

30
20

20 30 20
100
200
All Dimensions are in mm All Dimensions are in mm
Figure 4.3 Figure 4.4

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 Government of Karnataka
DEPARTMENT OF TECHNICAL EDUCATION

Program MECHANICAL ENGG Semester IV

Course Name Elements of Industrial Automation Type of Course Integrated
104
Course Code 25ME44I Contact Hours Hrs/Sem
Teaching Scheme L: T:P: [Link] Credits 5
50
CIE Marks 50 SEE Marks
(Practice)

9. Rationale:

In today's manufacturing landscape, industries are rapidly transitioning towards

complete automation. Small and medium-sized enterprises are increasingly adopting
PLC(Programmable Logic Controller) and Human Machine Interface (HMI) technologies for
data acquisition and process control. Industrial automation systems are used to monitor and
control processes, machines, or devices in a computerized manner, typically handling
repetitive tasks. These systems are designed to function autonomously, reducing the need for
human intervention and improving efficiency across the industry. The benefits of this
technology include higher production rates, increased productivity, more efficient material
usage, better product quality, improved safety, shorter workweeks for labor, and reduced
factory lead times. Automation engineers are responsible for designing, programming,
simulating, and commissioning automated machinery and plant-wide processes to perform
various functions. Depending on the size of the organization, the engineer may take on all or
part of these responsibilities. It is essential for diploma engineers to acquire knowledge of both
PLC and other automation technologies, as these are the backbone of industrial automation.

This course is designed to introduce the fundamental theoretical and practical concepts
of automation technologies, helping students develop the operational competencies needed in
this field. As a result, it serves as a foundational course for diploma engineers who wish to
specialize in industrial automation.

10. Course Out comes: At the end of the course, the student will be able to:
Select the appropriate sensor, actuator and other hardware components for a
CO-01
given automation application.
Integrate various hardware components to implement a specified automation
CO-02
system.
CO-03 Develop ladder program for simple automation applications.
Appreciate the application of automation concepts and technologies used in
CO-04
Industry 4.0.

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 11. Course Content
WEEK CO PO Theory Practice
Introduction to Industrial Study the following appliances/
Automation automation systems and identify
• History of Industrial Automation various elements used and their
(Industry 1.0 to Industry 4.0) function
• Benefits of Industrial • Air conditioning System
Automation/Need of Automation in • Washing Machine
Industry • Automatic Bottling System
• Types of Industrial Automation- • Automatic Packaging System
1 4 1,2,4 fixed, programmable, flexible(give at
least one example for each.) Write the Block Diagram for each
• Levels/ Hierarchy of Industrial of the above application by
Automation highlighting the importance of
• Standards used in industrial sensor/actuator and controller
automation(ISO, IEC, JIC) used.
• Basic Components of Automation
System with block diagram

Sensors and Transducers Interfacing following Industrial

 Classification of Sensors grade switches with simple
 Analog and Digital Sensors circuits for basic automation tasks
 Performance Terminology of • Push Buttons
Sensors • Toggle Switches
 IEC standard Symbols for • Emergency Stop
Switches/Sensors • Rotary Switches
Ref: • Key Switch
1, [Link] • Limit Switches
2 1,2,4
2 yout
Types of Sensors -Working Principle & Note: Give an industrial scenario
Industrial Applications with circuit for for each of these where specific
each of the following (Refer CIE QP) switches are essential.
a. Switches and Push buttons
b. Limit Switches
c. Proximity Sensors
d. Position/Displacement Sensor

Types of Sensors (Refer CIE QP) Interfacing following sensorswith

e. Pressure Switches simple circuits for basic
f. Liquid Level detectors automation tasks without using
g. Photoelectric Sensors/switches controller
1, h. Encoders • Float Sensor
3 1,2,4 i. Temperature Sensors • Proximity - Inductive,
2
j. Strain Gauges Capacitive and Optical (PNP &
k. Fluid Flow Measurement NPN)
l. Smart Sensors • Pneumatic Reed
m. Speed Sensors Switch(magnetic)

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 Actuators Interfacing following Actuators
• IEC standard Symbols for Actuators with simple circuits for basic
• Working Principle and Applications automation tasks without using
of Following devices controller
• Solenoid Actuators – Water • Use Water Solenoids and Float
Solenoid, Pneumatic DCVs switches to maintain Water
4 1,2 1,2,4 • Vacuum generators & Pneumatic Level
Gripper • Actuate DAC using double
• Relays-SPST, SPDT, DPST and DPDT solenoid 5/2 DCV(Electro-
Pneumatic Circuit)
• Run 12VDC Geared Motor
forward/ reverse using two
relays and Push buttons

Electric Motors Interfacing following Motors with

• DC Motors & DC Servo Motors motor Drivers for basic
• Stepper Motor automation tasks without using
• Synchronous Motors controller
5 1,2 1,2,4 • Servo Motors • DC Geared Motors with Driver
• Motor Drivers – Stepper Drivers, • Stepper Motor with Driver &
Servo Drivers, Variable Frequency Pulse Generator
Drives (VFDs) • AC Motors with VFD

Programmable Logic Controller(PLC) • Demonstrate Relay Logic

• History of PLC Circuit
• Relay Logic Circuits • PLC Hardware & Architecture
• Need of PLC for Industrial • Memory Organization
Automation • Familiarize with PLC - CPU, IO
• PLC Block Diagram Modules, Power Supply,
6 3 1,2,4 • Opto–Isolators Communications, IO Devices
• Need of Sink and Source type • Wiring the PLC
Wiring • Leading PLC manufacturers in
• Types of PLC based on outputs global market
• Analog to Digital Converters (ADCs)
& Digital to Analog Converter
(DACs)
PLC Programming Fundamentals Develop a Ladder diagram to
• Types of PLC Programming switch ON/OFF light using
Languages following
• Ladder Programming • AND, OR, NOT, NAND, NOR &
• Standard IEC Symbols XOR Logic. Note: Construct the
7 3 1,2,4 (Programming) above logics using NO/NC
• Basic Ladder Diagram –Rails, Rungs, contacts and Logical Instruction
Branch blocks
• NC, NO Contacts and Coil. • To develop a ladder program
• Need of Push Button for Industrial for “automatic door opening”
Application using optical sensor

3 1,2,4 Programming Concepts Develop a ladder diagram for the

8
• Latching - Latching and Unlatching following logic using Latching
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 Instructions Circuit, Latching Instructions,
• Internal Relays /Memory Bits– Internal Relays/Bits
Variable Declaration • Three level Safety Alarm
• Interlocks and Trips – Types and System
Need of Interlocks (Demonstrate • Develop a ladder diagram for
using three level alarm system) Automation of two Pneumatics
• Controlling Stepper Motor using cylinders in sequence
PWM Instruction Block • Develop a ladder diagram to
forward and Reverse stepper
motor using Driver: Use PWM
instruction block in Ladder
Programming

Programming Concepts Develop PLC ladder diagram and

• Timer - TON, TOFF interface the following Logics
• Timer - Sequencing, Cascading • Two tanks supplying liquids
• Counters – CTD,CTU, CTUD simultaneously to mixer based
• Math Instructions- *,+,-,/, MOD, Neg on requirement using timer
9 3 1,2,4 etc. Subtract the current liquid level instruction block
from the tank capacity to calculate • For counting the number of
available space- use level gauge. items moving on a conveyor
• Compare Instruction- <,>, <=,>=, belt
=,<> etc. Compare the temperature of a • Car Parking Barrier using Up-
process with a set point to control an Down Counter(CTUD)
output- use LM35 temperature sensor.
Programming Concept- Reading 
Develop a ladder diagram to
Analog inputs measure the water level using
 Instruction Blocks: Conversion of Level Gauge (Analog Input):
10 3 1,2,4 any variable to bool, int,real etc. Use “Any to Real” and
 SCALER Instruction Block “SCALAR” instruction blocks
 Lift for three floor
 Traffic Light Programming
PLC Pneumatics/ Hydraulics  Develop ladder diagram and
 Importance of PLC operate pneumatic actuation
Pneumatics/Hydraulics for the following logics
 Sensors & Actuators used in a. Cylinder Sequencing Circuit
Pneumatic/ Hydraulics circuits using Reed Switches
 Functions and features of pneumatic b. Clamp/unclamp based on
11 3 1,2,4 drives- Guided cylinders, rod less optical sensor input.
linear drives and rotary drives.  The develop PLC ladder
 Vacuum Generator and Gripper diagram and interface
 Industrial Application of PLC hardware components to
pneumatics. pneumatic gripper to pick up
objects from a conveyor belt
and place them in specific bins.
Advanced Industrial Automation& Case studies - Visit any one of the
Control Systems following industries and prepare a
• SCADA: Features, Typical SCADA concise report on their operations:
12 4 1,2,4
Systems- Petroleum Refining, Water  Milk Packing Unit
Purification, Chemical Plant.  Paint Industry
• HMI: Human-Machine Interface,  Food Packing Industries
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 Sample HMI Screens  Drinking Water Bottling Unit
• PAC: Programmable Automation Note: Collect information about
Controller- Benefits over PLC SCADA, HMI, DCS, PAC, RTU or any
• RTU: Remote Terminal Unit other automation system used in
• DCS: Distributed Control System the Industry.
[Link]
/case-studies/ as on 02/10/2024
Technologies driving Industry 4.0 Demonstrate following IoT
application using Arduino/
 IIoT, Cyber Security Raspberry-Pi board
 Artificial Intelligence, Machine  ArduinoIoT Program for
13 4 1,2,4 Learning Controlling an LED
 Big Data, Augmented Reality  ArduinoIoT Program for
 Digital Twin, Block Chain Reading Temperature and
Humidity using DHT11/DHT22
Sensor
12. References:
Sl.
Author Title of Books Publication/ Year
No.
Automation, Production Systems and 4thEdition, Pearson
1 Mikell P. Groover
Computer - Integrated Manufacturing Education, 2016
6th Edition, Newnes
2 W. Bolton Programmable logic Controllers
Publisher, 2015
Hand book of Modern Sensors, 4th ed. Springer-Verlag
3 Jacob Fraden
Physics, Designs and Applications New York Inc., 2014
Austin Hughes And 4thEdition, Newnes
4 Electric Motors and Drives
Bill Drury Publisher, 2013
Automating Manufacturing Systems
5 Hugh Jack Publisher: Lulu, 2009
with PLC
Springer
6 Shimon Y. N Springer Handbook of Automation
2009
SCADA: Supervisory Control and Data 4thEd, International Society
7 A_Boyer
Acquisition of Automation, 2016
Rajesh 1stEd, Laxmi Publications
8 PLCs & SCADA - Theory and Practice
Mehra&Vikrant Vij Private Limited, 2019

9 Samuel Greengard The Internet of things The MIT Press, 2015

10 Web Link : [Link]/case-studies/ as on 02/10/2024

8. CIE Assessment Methodologies

Sl.N Test Duration Max.
CIE Assessment
o Week (minutes) Marks
Average of all
1. CIE-1TheoryTest 4 90 50
CIE=50 Marks
2. CIE-2Practice Test 7 180 50

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 3 CIE-3TheoryTest 10 90 50

4. CIE-4Practice Test 13 180 50

CIE-5 Portfolio evaluation of all the Graded
5 exercises (25 Marks) and Activities (25 Marks) 1-13 50
through Rubrics
Total 50 Marks

10. SEE – Practice Assessment Methodologies

Sl. Duration Max. Min. Marks
SEE – Practice Assessment
No (minutes) Marks to Pass

1. Semester End Examination-Practice 180 50 20

11. CIE Theory Test Model Question Paper

Program Mechanical Engineering Semester - IV
Course Name Elements of Industrial Automation Test I/III
Course Code 25ME44I Duration 90 min Marks 50
Name of the Course Coordinator:
Note: Answer any one full question from each section. Each full question carries equal marks.
Cognitive Course
Q. No Questions Marks
Level Outcome
Section - 1
a. Describe how decisions are made at various levels of
industrial automation. Give an example of how field-level
Apply CO4 5
systems and management-level systems work together to
improve production efficiency.
b. In an automatic beverage bottle-filling system, explain the
functions of different sensors, actuators, and controllers Apply CO4 5
employed, along with a block diagram.
c. Discuss the advantages and disadvantages of fixed
automation versus flexible automation in a manufacturing
Apply CO4 5
1 setting. Provide an example of a scenario where each type
would be most beneficial.
d. Discuss the role of limit switches in automated machinery.
Identify a specific application where limit switches are
Apply CO1 5
critical and explain how they contribute to the overall
functionality of the system.
e. Give an industrial scenario for each of the following
switches where specific switches are essential) Push Apply CO1 5
Buttons ii) Key Switch
a. Describe how industrial automation improves quality
control in the manufacturing process. Provide a case
Apply CO4 5
where automation has been successfully applied to reduce
defects.
2 b. In a simple automatic food packaging system, explain the
functions of different sensors, actuators, and controllers Apply CO4 5
employed, along with a block diagram.
c. Discuss the benefits and drawbacks of fixed and
programmable automation in manufacturing processes. Apply CO4 5

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 Provide an example for each type that illustrates when it
would be most advantageous to use.
d. Discuss the importance of position or displacement
sensors in an industrial automation setup. Provide a
Apply CO1 5
practical example where these sensors significantly
impact the performance of a manufacturing process.
e. Give an industrial scenario for each of the following
switches where specific switches are essentiali) Toggle Apply CO1 5
Switch ii) Emergency Stop
Section –2
a. In a hydraulic system, explain how a pressure switch can
be used to monitor pressure levels. Design a simple circuit
Apply CO1 5
that activates an alarm if the pressure exceeds a specified
threshold.
b. In a water tank system, how can liquid level detectors be
employed to maintain optimal water levels? Create a
simple circuit that controls a pump to fill the tank when Apply CO1 5
the water level is low and turns it off when the level is
adequate.
c. In a packaging line, describe the application of
photoelectric sensors for detecting the presence of
products. Design a circuit that triggers a conveyor belt Apply CO1 5
3
when a product is detected, considering the need for
timely operation.
d. In a food processing plant, explain the role of temperature
sensors in ensuring product safety. Design a circuit that
activates a cooling system when temperatures exceed a Apply CO1 5
certain level, considering the requirement for rapid
response.
e. In a sewage treatment plant, how can float sensors be
implemented to manage waste levels? Create a simple
circuit that activates a pump to remove waste when a Apply CO1 5
certain level is detected, considering space and
environmental constraints
a. In an automated assembly line, how can proximity sensors
be used to detect the presence of parts? Create a circuit
that triggers an action (e.g., starting a machine) when a Apply CO1 5
part is detected, considering the need for quick cycle
times.
b. In an automated material handling system, how can
proximity sensors improve safety? Design a circuit that
Apply CO1 5
stops machinery if a person is detected within a hazardous
area, ensuring worker safety.
4
c. In a conveyor belt system, explain how limit switches can
prevent jamming. Create a circuit that stops the conveyor
Apply CO1 5
when a limit switch is triggered due to a blockage, focusing
on operational continuity.
d. In a water distribution system, how can fluid flow
measurement ensure system integrity? Design a circuit
that alerts operators when flow rates are outside Apply CO1 5
acceptable limits, considering the need for real-time
monitoring.

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 e. In a refrigeration unit, describe the role of temperature
sensors in maintaining optimal conditions. Design a circuit
Apply CO1 5
that turns on the compressor when the temperature rises
above a set point
Note for the Course coordinator: Each question may have two or three or four or five
subdivisions. Optional questions in each section carry the same weightage of marks, cognitive level
and course outcomes.

Signature of the Course Coordinator Signature of the HOD Signature of the IQAC Chairman

8. CIE Practice Test model question paper

Program Mechanical Engineering Semester IV
Course Name Elements of Industrial Automation Test II
Course Code 25ME44I Duration 180 min Marks 50
Name of the Course Coordinator:
Note:Answeranyonequestionfromeachsection.Eachquestioncarries25 marks
Questions CO Marks
Section-I
3. a. Design a circuit using push buttons (Start/Stop) to control the operation of a 1,2 25
conveyor belt. Use relays to handle the load without using a controller.
b. Design a basic automation circuit using an inductive proximity sensor to detect
metal objects.
c. Create a circuit using a float sensor to control the water level in a tank. Use a
water solenoid valve to automatically fill the tank when the level drops below a
set point.
d. Design a basic emergency stop switch circuit that shuts down a press machine
upon pressing the button.
e. Design a simple circuit using a float switch and a relay to automatically control
the pump.

Section-II
4. a. Design a pneumatic circuit to automatically reverse a double-acting cylinder 1,2 25
(DAC) using a magnetic reed switch, push button, 5/2 double solenoid valve, and
other essential pneumatic components.
b. Design a circuit using a VFD (Variable Frequency Drive) to control the speed of
an AC motor driving the conveyor belt.
c. Design a circuit that controls a stepper motor using a pulse generator for
accurate positioning of items on a conveyor.
d. Design a circuit using two relays and push buttons to control the forward and
reverse operation of a DC motor.
e. Develop a relay-based control circuit for a conveyor belt system that starts and
stops based on input from a proximity sensor (Inductive). Include an emergency
stop button to ensure safety during operation, simulating a scenario where metal
objects are detected on the conveyor.
Scheme of Assessment for Section I & II CO
a. Select the appropriate sensor, actuator and other hardware components for a
given automation application. 1 10x2
Note: Includes Aim of the practical, List of Components Required

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 b. Integrate various hardware components to design and implement automation
circuits.
2 15x2
Note: Includes Explanation, Procedure writing, Circuit diagram using IEC
standard Symbols, Execution and Inference/Result writing
Total Marks 50

Signature of the Course Coordinator Signature of the HOD

9. Suggestive Activities for Tutorials:

 The students shall do minimum of one suggested activities

 List is an Example and not inclusive of all possible activities of the course.
 Student and Faculty are encouraged to choose activities that are relevant to the topic.

[Link]. Suggestive Activities for Tutorials

Visit a nearby washing machine, refrigerator, or air conditioning repair shop. Observe and
study the system's various components. Record a video showing the operation and
components, and upload it to Google Classroom or any other platform as directed by the course
01
coordinator. Additionally, prepare a handwritten report (maximum 200 words) that includes a
block diagram of the system, illustrating how the components are interconnected, with a focus
on sensors, actuators, and controllers.
Create a ladder logic program to automate a "Water Level Controller" using Open PLC software.
Implement the program on an Arduino board and interface it with the necessary hardware
02
components to demonstrate its operation.
Reference: Open PLC Project Guide
Develop a simple relay circuit to switch ON/OFF an LED using TinkerCAD online simulation
03
[Link]: TinkerCAD
Design a ladder diagram to measure room temperature using an LM35 temperature sensor
04
and demonstrate the interfacing process.
Prepare a PowerPoint presentation on a proximity sensor manufactured by a selected
05 company. The presentation should include at least 10 slides.
Note: The course coordinator may assign each student a specific company and sensor type.
Visit one of the following industries: Milk Packing Unit, Paint Industry, Food Packing Industry,
or Drinking Water Bottling Unit. Prepare a concise report detailing the automation systems
used, including SCADA, HMI, DCS, PAC, RTU, or any other system.
06
Note: Collect information about SCADA, HMI, DCS, PAC and RTU or any other automation
system used in the Industry. [Link]/case-studies/ as on
02/10/2024

10. Rubrics for Assessment of Activity (Qualitative Assessment)

Sl. Unsatisfactory Satisfactory Good Very Good Excellent Student’s

Dimension
No 5 10 15 20 25 Score
In-depth
Limited Clear
Basic understanding Comprehensive
Understanding of understanding of understanding
understanding with ability to understanding with
1 Components/Syst system
with some key
with proper
explain deep insights into
10
ems components and explanation of
details missing component system operation
their functions components
relationships
Struggles with Able to Can complete Completes tasks Demonstrates
Technical Skills/ basic implement tasks tasks accurately with advanced technical
2 Implementation implementation with some independently minimal skills with flawless
15
of tasks assistance or with minor assistance execution
Department of Technical Education, Government of Karnataka 15
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 errors errors

Highly professional
Report/present Provides basic Well-organized Clear, concise,
presentation with
Report/Presentat ation lacks information, but report/presenta and in-depth
3 ion Quality clarity and lacks depth or tion with clear with appropriate
comprehensive 15
details and critical
detail organization details diagrams
insights
Limited Demonstrates a
Shows some Highly creative Exceptional creativity
creativity or creative
Creativity and creativity but approach with and innovative
4 Problem Solving problem-
limited problem-
approach with
strong problem- problem-solving,
20
solving in the good problem-
solving skills solving abilities with original insights
approach solving
Average Marks=(10+15+15+20)/4=15 15/25
Note: Dimension and Descriptor shall be defined by the respective course coordinator as per the activities

11. SEE- Model Practice Question Paper

Program Diploma in Mechanical Engineering Semester IV
Elements of Industrial
Course Name Course Code: 25ME44I Duration 180 min
Automation
Note: Answer any one question
Questions CO Marks
Note: During the SEE, All questions will be distributed among the group. Each student will be 1,2 50
assigned one of the following questions by the examiner, without offering any choice.
1. For an automatic door system using an optical sensor, select the appropriate sensor,
actuator, and other necessary hardware components. Develop a ladder program that
controls the door's opening and closing.
2. Design a pneumatic system that automates the sequencing of two cylinders. Identify the
suitable sensors and actuators for this application and integrate them into a functional
system. Write a ladder program for cylinder sequencing.
3. For a three-level safety alarm system, select the appropriate sensors and internal relays
to trigger alarms based on certain conditions. Develop a ladder program using latching
instructions.
4. Select and interface the required components for a water level monitoring system using
an analog level gauge. Write a ladder program using "Any to Real" and "SCALAR"
instruction blocks to measure and display the water level.
5. For a mixer system where two tanks supply liquids simultaneously, select the proper
sensors, actuators, and timers to control the flow. Develop a ladder program using timers
for this automation.
6. Design an automation system for controlling a conveyor belt. Choose the appropriate
hardware to count items moving on the belt and then develop a ladder program to
manage the counting.
7. For a lift system that operates between three floors, identify the necessary sensors,
actuators, and other hardware. Develop a ladder program to control the lift’s movement,
including the detection of floor levels.
8. Select the sensors and actuators for controlling a traffic light system at an intersection.
Integrate the components and write a ladder program to manage the light sequencing
based on a timer.
9. For a car parking barrier system, identify the necessary sensors, actuators, and timer
instruction blocks. Develop a ladder program to automate the opening and closing of the
barrier.
10. Develop an automation system for a pneumatic gripper that picks objects from a

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 conveyor belt and places them in bins. Select and integrate the appropriate sensors,
actuators, and hardware, then write a ladder program for the gripper’s operation.
Scheme of Assessment
a. Select the appropriate sensor, actuator and other hardware components for a given
automation application. CO1 5
Note: Includes Aim of the practical, List of Components Required
b. Integrate different hardware components with a Programmable Logic Controller (PLC)
for a specified automation system.
CO2 15
Note: Includes Explanation, Procedure writing and Circuit diagram using IEC standard
Symbols in addition to PLC integration with input and output components.
c. Develop ladder program for given automation applications, download and automating
the system
CO3 30
Note: Includes ladder programming and result writing in addition to automating the given
problem.
Total Marks 50

4) Signature of the Examiner 2) Signature of the Examiner

12. Equipment/softwarelistwithSpecificationforabatchof30students

[Link]
Particulars Specification Qty.
.
01 Computers Latest Configuration 10
Minimum 12, 24V DC Inputs, 4 configurable analog input with
thermistor voltage reference out, 7 24V DC Source Output, 1 Analog
Programmable Logic
02 Output, Embedded Ethernet Port and RS-232/485 non-isolated Serial 10
Controller (PLC)
port, Embedded RTC, MicroSD Card support and minimum 2 Plug-In
slots.
03 24 VDC Power Supply 24 V, 10A DIN Rail Mountable 10

04 12 VDC Power Supply 12 V, 5 A, DIN Rail Mountable 10

Push Button Industrial Grade with NO and NC Elements- 22 mm
05 Push Button 50
diameter
06 Key Switch Key Switch with NO and NC Elements - 22 mm diameter 5
07 Rotary Switch 2/3 Position Rotary Switches with NO Elements - 22 mm diameter 15 Each

Industrial Grade Mushroom Types switch with NC element -22 mm

08 Emergency Stop 10
diameter
09 Toggle Switch 2/3 Position Toggle Switch 5 Each

10 Float Sensor Float Sensor for Water Level detection 10

11 Buzzer 24VDC, 22mm 04
12 Level Gauge Analog Water Level Gauge ( minimum 30 cm Height) 02
13 Limit Switches Industrial Grade Roller Type/lever operated Limit Switch (NO/NC) 10
Proximity Sensors Inductive, Capacitive and Optical Proximity Sensors 20
14
(PNP Only) (Available Size M8/M12/M18/M30 diameter) Each

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 Pneumatic Reed Pneumatic Magnetic Reed Switch NO/NC,
15 10
Switch Used in Pneumatic Cylinder
15 Water Solenoids 24 VDC water Solenoid 10
16 Geared Motor DC Geared Motor 10
17 Pneumatic Cylinder 20 mm bore 100/150 mm stroke 6
Dual rod cylinder with guide function for pick & place applications,
18 Twin Cylinder 2
10/12 mm rod diameter, 125 mm stroke length
Direction Control
19 5/2 Single Solenoid DCV 2
Valve (DCV)
Direction Control
20 5/2 Double Solenoid DCV 2
Valve(DCV)
Direction Control
21 3/2 single Solenoid DCV 2
Valve(DCV)
Pneumatic vacuum
22 0.5 to 10 BAR 2
Generator
Vacuum Suction Cup
23 Round, oval, and bellow shaped 2
Gripper
24 Stepper Motor NEMA 23 Stepper motor 10kg/cm, 4 wired 4
TB6600 Stepper Motor Driver Controller 4A 9~42V TTL 16 Micro-
25 Stepper Driver 4
Step
Stepper Motor Driver Controller 8A Dual Mode Function Signal
26 Pulse Generator Generator, 1Hz-150KHz PWM Motor Speed Regulation/LCD Pulse 2
Frequency Cycle Module Adjustable Driver Module Signal Generator
27 AC Motor 3 Phase AC Motors 1
AC drive which offer a power rating of 0.4...22 kW (0.5...30 Hp) with
Variable Frequency
28 global voltage classes of 100...600V, provide a variety of motor 1
Drive(VFD)
control and flexible mounting options.
The trainer must be a miniature model of a three/four-layer elevator,
fully replicating real elevator functions with easy PLC interfacing. It
29 Lift Model provides hands-on training in PLC programming, sensor integration, 1
position control, and sequential logic control for elevator automation
systems.
The trainer should feature a DC geared motor-operated flat belt
conveyor, 3.5-inch width and minimum 2 feet length, easily
30 Conveyor Model interfaced with PLC. It provides hands-on training in PLC 1
programming, motor control, and automation processes, simulating
real-world conveyor operations.
The trainer should be a miniature model of a car parking barrier
system with functional entry and exit arms, similar to those at toll
31 Car Parking Barrier 1
plazas, easily interfaced with PLC. It should also include car full
indicators that activate when parking capacity is reached.
The trainer should be a miniature model of an Automatic Door Open-
Close System powered by a DC-geared motor, incorporating optical
Automatic Door Open sensors and limit switches for accurate motion detection and control.
32 1
Close System The model should be easily interfaced with a PLC, providing hands-
on training in motor control, sensor integration, and sequential logic
operations.
The trainer should be a miniature model of an industrial Mixer
System with water solenoids for precise control in each jar. It should
33 Mixer Model 1
feature PLC-interfaced controls for automatic or manual operation of
the mixing cycles.

Department of Technical Education, Government of Karnataka 15

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