TABLE OF CONTENTS

TABLE OF CONTENTS ...........................................................................................

CHAPTER 1 INTRODUCTION TO MECHANICAL ENGINEERING ...................
Glossary list 1 ................................................................................................
Reading 1: Introduction to mechanical engineering ....................................
Glossary list 2 ...............................................................................................
Reading 2: Sub disciplines of mechanical engineering ...............................
CHAPTER 2 ENGINEERING MATERIALS ...........................................................
CHAPTER 3 PROPERTIES OF MATERIALS .........................................................
CHAPTER 4 TOOL OPERATION .............................................................................
CHAPTER 5 WORKSHOP PROCESS .....................................................................
CHAPTER 6 GRAPHS AND TABLES .....................................................................
REFERENCES ...........................................................................................................
 CHAPTER 1
INTRODUCTION TO MECHANICAL ENGINEERING

GLOSSARY LIST 1

Mechanical engineering : Teknik mesin

Mechanical engineer : Insinyur mesin
Aerospace engineering : Teknik penerbangan
Civil engineering : Teknik sipil
Electrical engineering : Teknik elektro
Chemical engineering : Teknik kimia
Industrial engineering : Teknik industri
Design : Perancangan
Analysis : Analisis
Manufacturing : Pembuatan
Maintenance : Perawatan
Tool : Alat
Heating and cooling systems : Sistem penghangat dan pendingin
Prototype : Prototipe (Model awal yang dijadikan contoh)
Composite : Material yang tersusun atas campuran dua atau
lebih material dengan sifat kimia dan fisika
yang berbeda
Dynamics : cabang dari ilmu fisika yang mempelajari gaya
dan torsi dan efeknya pada gerak
Thermodynamics : Bagian dari ilmu fisika yang mempelajari
energi panas, temperatur, dan hukum-hukum
tentang perubahan energi panas menjadi
energi mekanik
 READING 1

INTRODUCTION TO MECHANICAL ENGINEERING

Mechanical engineering is the discipline that applies engineering physics, engineering

mathematics, and materials science principles to design, analyze, manufacture, and maintain
mechanical systems. It is one of the oldest and broadest of the engineering disciplines.

The mechanical engineering field requires an understanding of core areas including

mechanics, dynamics, thermodynamics, materials science, structural analysis, and electricity.
In addition to these core principles, mechanical engineers use tools such as computer-aided
design (CAD), computer-aided manufacturing (CAM), and product lifecycle management to
design and analyze manufacturing plants, industrial equipment and machinery, heating and
cooling systems, transport systems, aircraft, watercraft, robotics, medical devices, weapons,
and others. It is the branch of engineering that involves the design, production, and operation
of machinery.

Mechanical engineering emerged as a field during the Industrial Revolution in Europe

in the 18th century. In the 19th century, developments in physics contributed to the
advancement of mechanical engineering science. The field has continually evolved to
incorporate advancements; today mechanical engineers are pursuing developments in such
areas as composites, mechatronics, and nanotechnology. It also overlaps with aerospace
engineering, civil engineering, electrical engineering, manufacturing engineering, chemical
engineering, industrial engineering, and other engineering disciplines. Mechanical engineers
may also work in the field of biomedical engineering, specifically with biomechanics,
transport phenomena, bio mechatronics, bio nanotechnology, and modelling of biological
systems.

Mechanical engineers research, design, develop, build, and test mechanical and
thermal devices, including tools and machines.

Mechanical engineers typically do the following:

 Analyze problems to see how mechanical and thermal devices might help solve the
problem.
  Design or redesign mechanical and thermal devices using analysis and computer-aided
design.
 Develop and test prototypes of devices they design.
 Analyze the test results and change the design as needed.
 Oversee the manufacturing process for the device.

Mechanical engineers design and oversee the manufacturing of many products ranging
from medical devices to new batteries. They also design power-producing machines such as
electric generators, internal combustion engines, and steam and gas turbines as well as
power-using machines, such as refrigeration and air-conditioning systems. Like other
engineers, mechanical engineers use computers to help create and analyze designs, run
simulations and test how a machine is likely to work.

READING TASKS

Task 1. State whether these statements are true (circle T) or false (circle F) according
to the information stated on the reading passage!

1. Mechanical engineering does not overlap with other engineering disciplines.

[ T/F ]

2. Mechanical engineering is a discipline that appeared for the first time after the 19 th
century.

[ T/F ]

3. Mechanical engineers’ job duty is not only about maintaining machines.

[ T/F ]

4. In the 18th century, mechanical engineers manufactured machines using computer-

aided manufacturing.

[ T/F ]

5. Mechanical engineers do not merely manufacture machines for household electronic

appliance

[ T/F ]
 6. Computers ease mechanical engineers to create and analyze designs, run simulations
and test how a machine is likely to work.

[ T/F ]

7. Physics and mathematics are mandatory to be studied by mechanical engineer

students.

[ T/F ]

8. Mechanical engineers analyze structure only to find problems.

[ T/F ]

9. In the current era, mechanical engineers manufacture machines more sophisticatedly.

[ T/F ]

10. Mechanical engineering is the only branch in the engineering discipline.

[ T/F ]

Task 2. Using your own opinion, answer the following questions!

1. In your opinion, are jobs related to mechanical engineering still high in demand
nowadays? State your reason(s)!

_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

2. What skills do mechanical engineers need to master in the 21st century? Explain why
those skills are important to be mastered!

_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
3. What challenges that mechanical engineers may encounter in the field?

_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

4. How important is the role of Information and Communication Technology (ICT) to

support the job of mechanical engineers?

_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________

5. How can mechanical engineers contribute to society?

_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
 GLOSSARY LIST 2

Subdisciplines : Cabang-cabang ilmu

Force : Gaya (dorongan atau tarikan yang timbul karena gravitasi atau
magnet yang mengakibatkan percepatan)
Matter : Objek
Movement : Gerak
Velocity : Kecepatan
Acceleration : Percepatan
Deformation : Perubahan bentuk
Fluid : Zat fluida (cair, gas, dan plasma)
Frame of vehicle : Bodi kendaraan
Labor : Tenaga kerja
Assembly line : Perakitan
Factory : Pabrik
Fatigue : Kelelahan (melemahnya suatu bahan yang disebabkan oleh
beban yang berkali-kali diaplikasikan terhadap bahan tersebut)
Failure : Kegagalan
Failure analysis : Analisis kegagalan
Cause : Penyebab
Crack : Retakan
Heat transfer : Perpindahan panas
Power plants : Pembangkit listrik
Fabrication : Pembuatan
Energy conversion : Konversi (perubahan) energi
Radiator : Alat penukar panas yang digunakan untuk memindahkan
energi panas dari satu medium ke medium lainnya yang
berfungsi untuk mendinginkan mesin
Heat sink : Alat pembuang panas
 READING 2

SUBDICIPLINES OF MECHANICAL ENGINEERING

The field of mechanical engineering can be thought of as a collection of many

mechanical engineering science disciplines. Several of these sub disciplines which are
typically taught at the undergraduate level are listed below, with a brief explanation and the
most common application of each. Some of these sub disciplines are unique to mechanical
engineering, while others are a combination of mechanical engineering and one or more
other disciplines. Most work that a mechanical engineer does uses skills and techniques from
several of these sub disciplines, as well as specialized sub disciplines. Specialized sub
disciplines, as used in this article, are more likely to be the subject of graduate studies or on-
the-job training than undergraduate research. Several specialized sub disciplines are
discussed in this section.

Mechanics
Mechanics is, in the most general sense, the study of forces and their effect upon
matter. Typically, engineering mechanics is used to analyze and predict the acceleration and
deformation (both elastic and plastic) of objects under known forces (also called loads) or
stresses. Sub disciplines of mechanics include:

 Statics, the study of non-moving bodies under known loads, how forces affect static
bodies.
 Dynamics the study of how forces affect moving bodies. Dynamics includes
kinematics (about movement, velocity, and acceleration) and kinetics (about forces
and resulting accelerations).
 Mechanics of materials, the study of how different materials deform under various
types of stress.
 Fluid mechanics, the study of how fluids react to forces.
 Kinematics, the study of the motion of bodies (objects) and systems (groups of
objects), while ignoring the forces that cause the motion. Kinematics is often used in
the design and analysis of mechanisms.
 Continuum mechanics, a method of applying mechanics that assumes that objects are
continuous (rather than discrete).
 Mechanical engineers typically use mechanics in the design or analysis phases of
engineering. If the engineering project were the design of a vehicle, statics might be
employed to design the frame of the vehicle, in order to evaluate where the stresses will be
most intense. Dynamics might be used when designing the car's engine, to evaluate the
forces in the pistons and cams as the engine cycles. Mechanics of materials might be used to
choose appropriate materials for the frame and engine. Fluid mechanics might be used to
design a ventilation system for the vehicle, or to design the intake system for the engine.

Mechatronics and robotics

Mechatronics is a combination of mechanics and electronics. It is an interdisciplinary
branch of mechanical engineering, electrical engineering and software engineering that is
concerned with integrating electrical and mechanical engineering to create hybrid systems. In
this way, machines can be automated through the use of electric motors, servo-mechanisms,
and other electrical systems in conjunction with special software. A common example of a
mechatronics system is a CD-ROM drive. Mechanical systems open and close the drive, spin
the CD and move the laser, while an optical system reads the data on the CD and converts it
to bits. Integrated software controls the process and communicates the contents of the CD to
the computer.

Robotics is the application of mechatronics to create robots, which are often used in
industry to perform tasks that are dangerous, unpleasant, or repetitive. These robots may be
of any shape and size, but all are preprogrammed and interact physically with the world. To
create a robot, an engineer typically employs kinematics (to determine the robot's range of
motion) and mechanics (to determine the stresses within the robot).

Robots are used extensively in industrial engineering. They allow businesses to save
money on labor, perform tasks that are either too dangerous or too precise for humans to
perform them economically, and to ensure better quality. Many companies employ assembly
lines of robots, especially in Automotive Industries and some factories are so robotized that
they can run by themselves. Outside the factory, robots have been employed in bomb
disposal, space exploration, and many other fields. Robots are also sold for various
residential applications, from recreation to domestic applications.
Structural analysis
Structural analysis is the branch of mechanical engineering (and also civil
engineering) devoted to examining why and how objects fail and to fix the objects and their
performance. Structural failures occur in two general modes: static failure, and fatigue
failure. Static structural failure occurs when, upon being loaded (having a force applied) the
object being analyzed either breaks or is deformed plastically, depending on the criterion for
failure. Fatigue failure occurs when an object fails after a number of repeated loading and
unloading cycles. Fatigue failure occurs because of imperfections in the object: a
microscopic crack on the surface of the object, for instance, will grow slightly with each
cycle (propagation) until the crack is large enough to cause ultimate failure.

Failure is not simply defined as when a part breaks, however; it is defined as when a
part does not operate as intended. Some systems, such as the perforated top sections of some
plastic bags, are designed to break. If these systems do not break, failure analysis might be
employed to determine the cause.

Structural analysis is often used by mechanical engineers after a failure has occurred,
or when designing to prevent failure. Engineers often use online documents and books such
as those published by ASM to aid them in determining the type of failure and possible
causes.

Once theory is applied to a mechanical design, physical testing is often performed to

verify calculated results. Structural analysis may be used in an office when designing parts,
in the field to analyze failed parts, or in laboratories where parts might undergo controlled
failure tests.

Thermodynamics and thermo-science

Thermodynamics is an applied science used in several branches of engineering,
including mechanical and chemical engineering. At its simplest, thermodynamics is the study
of energy, its use and transformation through a system. Typically, engineering
thermodynamics is concerned with changing energy from one form to another. As an
example, automotive engines convert chemical energy (enthalpy) from the fuel into heat, and
then into mechanical work that eventually turns the wheels.
 Thermodynamics principles are used by mechanical engineers in the fields of heat
transfer, thermo fluids, and energy conversion. Mechanical engineers use thermo-science to
design engines and power plants, heating, ventilation, and air-conditioning (HVAC) systems,
heat exchangers, heat sinks, radiators, refrigeration, insulation, and others.

Design and drafting

Drafting or technical drawing is the means by which mechanical engineers design
products and create instructions for manufacturing parts. A technical drawing can be a
computer model or hand-drawn schematic showing all the dimensions necessary to
manufacture a part, as well as assembly notes, a list of required materials, and other pertinent
information. A U.S. mechanical engineer or skilled worker who creates technical drawings
may be referred to as a drafter or draftsman. Drafting has historically been a two-
dimensional process, but computer-aided design (CAD) programs now allow the designer to
create in three dimensions.

Instructions for manufacturing a part must be fed to the necessary machinery, either
manually, through programmed instructions, or through the use of a computer-aided
manufacturing (CAM) or combined CAD/CAM program. Optionally, an engineer may also
manually manufacture a part using the technical drawings. However, with the advent of
computer numerically controlled (CNC) manufacturing, parts can now be fabricated without
the need for constant technician input. Manually manufactured parts generally consist of
spray coatings, surface finishes, and other processes that cannot economically or practically
be done by a machine.

Drafting is used in nearly every sub discipline of mechanical engineering, and by

many other branches of engineering and architecture. Three-dimensional models created
using CAD software are also commonly used in finite element analysis (FEA) and
computational fluid dynamics (CFD).
 READING TASK

Answer the following questions based on the passage that you have read!

1. How many sub disciplines of mechanical engineering mentioned in the passage?

Mention them!

_____________________________________________________________________

2. What is the main concern of structural analysis?

_____________________________________________________________________

3. What are the products that can be made through mechatronics system?

_____________________________________________________________________

4. Why robots are used massively in industrial engineering?

_____________________________________________________________________

5. What is the breakthrough resulted from computer-aided design (CAD) on the process
of design?

_____________________________________________________________________

6. What is the main thing that engineering thermodynamics concerns about?

_____________________________________________________________________

7. How can fatigue failure occurs?

_____________________________________________________________________

8. What is the main difference between statics and dynamics?

_____________________________________________________________________

9. How can hybrid system be created?

_____________________________________________________________________

10. What are the products that can be created by mechanical engineering by using
thermo-science?

_____________________________________________________________________
 WRITING SECTION

PRE-WRITING

TENSES

Simple Present Tense

Tense ini digunakan untuk menyatakan fakta atau kebenaran umum dan juga untuk
menyatakan kejadian yang dilakukan secara terus-menerus (kebiasaan, hobi, dll). Tense ini
juga biasa digunakan untuk mendeskripsikan orang, benda, tempat, maupun ilmu
pengetahuan seperti untuk menjelaskan ilmu teknik mesin.

Fakta

Matahari terbit dari timur The sun rises from the east

Kediri adalah sebuah kota dari negara Kediri is a city from Indonesia
Indonesia

Real Madrid menjuarai Liga Champion Real Madrid wins Europe Champions
Eropa sebanyak 12 kali League 12 times

Kebiasaan / Hobi

Andi berlatih sepakbola setiap akhir Andi practices football every weekend
pekan

Sinta selalu mengerjakan pekerjaan Sinta always does her homework on time
rumahnya tepat waktu

Dani sangat senang bermain Mobile Dani really likes playing Mobile Legends
Legends

Deskripsi

Teknik mesin adalah sebuah ilmu yang
menerapkan prinsip fisika, matematika,
dan ilmu bahan untuk merancang,
menganalisa, membuat, dan merawat
sistem-sistem pada mesin.
Mechanical engineering is the discipline
that applies engineering physics,
engineering mathematics, and materials
science principles to design, analyze,
manufacture, and maintain mechanical
systems.
Rumus Simple Present Tense

Verbal sentence (terdapat kata kerja utama (main verb) dalam kalimat)

S+V1 (S/ES) + compliment (noun/adjective/adverb)

*V1 digunakan untuk subject I, You, They, We

*V s/es digunakan untuk subject She, He, It

Example:

She Eats Rice everyday

S Main verb (S/ES) Noun (O) Adverb

I Eat Rice everyday

S Main verb 1 Noun (O) Adverb

Non-verbal sentence (tidak terdapat kata kerja utama (main verb) dalam kalimat)

S+ to be 1 (is/am/are) + compliment (noun/adjective/adverb)

*to be 1 “am” digunakan untuk subject I

*to be 1 “are” digunakan untuk subject You dan We

*to be 1 “is” digunakan untuk subject He, She, It

Example:

I am Handsome

S To be 1 (am) Adjective

He is Handsome

S To be 1 (is) Adjective

You are Handsome

S To be 1 (are) Adjective
 PRE-WRITING TASKS
TASK 1 State whether these sentences belong to verbal (write V) or nominal
sentences (write N)!
1. Thermodynamics is a science [ ]
2. Mechanical engineering has many sub disciplines [ ]
3. Some mechanical engineers work in the field [ ]
4. CAD is important in mechanical engineering [ ]
5. Fatigue failure occurs because of imperfections in the object [ ]

TASK 2 Complete these sentences with the correct main verbs!

1. Budi and Dimas ________ as mechanical engineers
(work/works)
2. Engineering physics ________ crucial roles in mechanical engineering discipline
(take/takes)
3. Mechanical engineers ________ thermo-science to design engines and power plants
(use/uses)
4. Automotive engines ________ chemical energy (enthalpy) from the fuel into heat
(convert/converts)
5. Manufactured parts generally ________ of spray coatings, surface finishes, and other
processes that cannot economically or practically be done by a machine.
(contain/contains)

TASK 3 State whether these non-verbal sentences use is, am, or are!
1. Mr. Drian ________ my favorite mechanical engineering lecturer
2. My classmates ________ interested in structural analysis
3. We ________ late for project submission on thermodynamics subject
4. I ________ not good at thermo-science
5. Tina and Rudi ________ the representatives of our university for international
mechanical engineering contest in USA
 WRITING TASKS
TASK 1 Create 5 (five) verbal sentences which contain these main verbs!
1. Convert : __________________________________________________________
2. Maintain : __________________________________________________________
3. Prevent : __________________________________________________________
4. Design : __________________________________________________________
5. Manufacture: __________________________________________________________

TASK 2 Create 5 (five) non-verbal sentences which contain these words!

1. Force : __________________________________________________________
2. Velocity : __________________________________________________________
3. Stress : __________________________________________________________
4. Prototype : __________________________________________________________
5. Dynamics : __________________________________________________________

TASK 3 Working in group, write a description on the following topics:

Group 1: What is mechanical engineering (in general)
Group 2: Sub discipline of mechanical engineering (mechanics)
Group 3: Sub discipline of mechanical engineering (Mechatronics and robotics)
Group 4: Sub discipline of mechanical engineering (Structural analysis)
Group 5: Sub discipline of mechanical engineering (Thermodynamics and thermo-science)

Notes:
 Your writing must be about 200-300 words
 Type your writing using these settings:
1. A4 paper size
2. Times New Roman (size 12)
3. Justify paragraph
4. 1,5 space
5. Margin (top 3cm, left 4cm, right 3cm, bottom 3cm)
 Do not copy contents from internet!
 CHAPTER 2
ENGINEERING MATERIALS

VOCABULARIES

Alloy : paduan Fracture : patahan; retakan

Brittle : getas; rapuh Load : beban
Briquette : Briket Metal : Logam
Ceramic : keramik Polymer : polimer
Composite : komposit Stiff : kaku; keras
Corrosion : karat; korosi Stiffenes : kekakuan
Creep : mulur Stress : tekanan
Tension : tegangan Impact stress : tegangan tumbuk
Heat treatment : perlakuan panas Impact Strength : kekuatan kejut
Fatigue fracture : keretakan lelah Fragile : rapuh; dapat pecah; lemah
Deformation : perubahan bentuk; deformasi
Yield strenght : kuat luluh ; tegangan luluh
Yield point : titik patah; batas kenyalan; batas lumer
Ductility : sifat dapat diregang; sifat dapat dikempa
Ductile : dapat diregang; dapat dikempa; dapat bengkok
Toughness : keuletan; daya tahan suatu bahan terhadap lenturan dan
puntiran berulang-ulang
 READING
ENGINEERING MATERIALS
It is conventional to classify the materials of engineering into the six broad classes
shown in Figure 1.1 : metals, polymers, elastomers, ceramics, glasses and composites. The
members of a class have features in common: similar properties, similar processing routes,
and, often, similar applications.
Metals have relatively high moduli. They can be made strong by alloying and by
mechanical and heat treatment, but they remain ductile, allowing them to be formed by
deformation processes. Certain high-strength alloys (spring steel, for instance) have
ductilities as low as 2%, but even this is enough to ensure that the material yields before it
fractures and that fracture, when it occurs, is of a tough, ductile type. Partly because of their
ductility, metals are prey to fatigue and of all the classes of material, they are the least
resistant to corrosion.
Ceramics and glasses, too, have high moduli, but, unlike metals, they are brittle. Their
strength in tension means the brittle fracture strength; in compression it is the brittle crushing
strength, which is about 15 times larger. And because ceramics have no ductility, they have a
low tolerance for stress concentrations (like holes or cracks) or for high contact stresses (at
clamping points, for instance). Ductile materials accommodate stress concentrations by
deforming in a way which redistributes the load more evenly; and because of this, they can
be used under static loads within a small margin of their yield strength. Ceramics and glasses
cannot. Brittle materials always have a wide scatter in strength and the strength itself
depends on the volume of material under load and the time for which it is applied. So
ceramics are not as easy to design with as metals. Despite this, they have attractive features.
They are stiff, hard and abrasion-resistant (hence their use for bearings and cutting tools);
they retain their strength to high temperatures; and they resist corrosion well. They must be
considered as an important class of engineering material.
Polymers and elastomers are at the other end of the spectrum. They have moduli
which are low, roughly so times less than those of metals, but they can be strong - nearly as
strong as metals. A consequence of this is that elastic deflections can be large. They creep,
even at room temperature, meaning that a polymer component under load may, with time,
acquire a permanent set. And their properties depend on temperature so that a polymer which
is tough and flexible at 20°C may be brittle at the 4°C of a household refrigerator, yet creep
rapidly at the 100°C of boiling water. None have useful strength above 200°C. If these
aspects are allowed for in the design, the advantages of polymers can be exploited. And there
are many. When combinations of properties, such as strength per- unit-weight, are important,
polymers are as good as metals. They are easy to shape: complicated parts performing
several functions can be moulded from a polymer in a single operation. The large elastic
deflections allow the design of polymer components which snap together, making assembly
fast and cheap. By accurately sizing the mould and pre-colouring the polymer, no finishing
operations are needed. Polymers are corrosion resistant, and they have low coefficients of
friction. Good design exploits these properties.
Composites combine the attractive properties of the other classes of materials while
avoiding some of their drawbacks. They are light, stiff and strong, and they can be tough.
Most of the composites at present available to the engineer have a polymer matrix - epoxy or
polyester, usually reinforced by fibers of glass, carbon or Kevlar. They cannot be used above
250°C because the polymer matrix softens, but at room temperature their performance can be
outstanding. Composite components are expensive and they are relatively difficult to form
and join. So despite their attractive properties the designer will use them only when the
added performance justifies the added cost.
 Figure 1.1 The menu of engineering materials.

The classification of Figure 1.1 has the merit of grouping together materials which
have some commonalty in properties, processing and use. But it has its dangers, notably
those of specialization (the metallurgist who knows nothing of polymers) and of conservative
thinking ('we shall use steel because we have always used steel'). In later chapters we
examine the engineering properties of materials from a different perspective, comparing
properties across all classes of material. It is the first step in developing the freedom of
thinking that the designer needs.

READING TASKS