Introduction to Mechanical Engineering

Role of Mechanical Engineers in Society

Transportation
➢ The distance that once took days for us to cover using biological modes of transport can
now be achieved in mere hours and minutes with the aid of automobiles.

Department of Mechanical Engineering, MCE, Hassan 1

Introduction to Mechanical Engineering

Role of Mechanical Engineers in Society

Agricultural mechanization
➢ The agricultural field too reaped the benefits of modified mechanized farming
machinery to increase the production and reduce the time taken to do so manually.
➢ Without the implementation of the modern machinery like water pumps, tractors,
harvesters, etc. developed by the mechanical engineers, our society would have been
still hobbled and would have never attained its full potential.

Department of Mechanical Engineering, MCE, Hassan 2

Introduction to Mechanical Engineering

Role of Mechanical Engineers in Society

Agricultural mechanization

Department of Mechanical Engineering, MCE, Hassan 3

Introduction to Mechanical Engineering

Role of Mechanical Engineers in Society

Household appliances
➢ Comfortable life with the help of appliances such as heaters, air conditioners, and
refrigerators.
➢ Every workplace in the modern world has a ventilated central cooling and/or heating
system. Such systems are also used to purify the air and help in manufacturing processes
that require a specific temperature.

Department of Mechanical Engineering, MCE, Hassan 4

Introduction to Mechanical Engineering

What you think of this appliance?

Electronic appliance

Thermal Engineering

Department of Mechanical Engineering, MCE, Hassan 5

Introduction to Mechanical Engineering

What you think of this appliance?

Electronic appliance

Design Engineering, Mechanics

Department of Mechanical Engineering, MCE, Hassan 6

Introduction to Mechanical Engineering

What you think of this picture?

Carpenter

Industrial engineering, Ergonomics

Department of Mechanical Engineering, MCE, Hassan 7

Introduction to Mechanical Engineering

What you think of this device?

Clock

Mechanics, Material Science

Department of Mechanical Engineering, MCE, Hassan 8

Introduction to Mechanical Engineering

What you think of this picture?

Pen

Hydraulics

Department of Mechanical Engineering, MCE, Hassan 9

Introduction to Mechanical Engineering

What you think of this picture?

Locks

Design, Mechanics

Department of Mechanical Engineering, MCE, Hassan 10

Introduction to Mechanical Engineering

What you think of this picture?

Guitar

Acoustic Engineering

Department of Mechanical Engineering, MCE, Hassan 11

Introduction to Mechanical Engineering

What you think of this picture?

Bungee jumping

Structural Analysis

Department of Mechanical Engineering, MCE, Hassan 12

Introduction to Mechanical Engineering

What you think of this picture?

Elevators

Mechanics, Mechatronics

Department of Mechanical Engineering, MCE, Hassan 13

Introduction to Mechanical Engineering

Role of Mechanical Engineers in Society

Waste management
➢ Waste management has also played a pivotal role in our society by keeping it clean,
hygienic and free of diseases.
➢ Waste disposal trucks, treatment facilities, and water purification systems are all
significant contributions of mechanical engineers towards our society.

Department of Mechanical Engineering, MCE, Hassan 14

Introduction to Mechanical Engineering

Role of Mechanical Engineers in Society

Other sectors
➢ Healthcare industry in creating technologies that are helping doctors and humankind
through solving various healthcare problems and creating future solutions.
➢ Healthcare devices, individualized medicines as well as surgical devices are being
developed by mechanical engineers using 3D-printing technologies.
➢ Mechanical engineers also involve in developing green technology, sustainable energy,
clean air, drinking water, green transportation, safe waste disposal and renewable
energy.

Department of Mechanical Engineering, MCE, Hassan 15

Introduction to Mechanical Engineering

Role of Mechanical Engineers in Energy Sector

➢ Mechanical engineers help hydropower or hydroelectric power plants find efficient ways of
extracting electricity from strong water currents.
➢ They design, and develop essential machines and hardware, such as turbines, generators, and
hydro-pressure and control mechanisms.
➢ Mechanical engineers can work in every stage of renewable energy development and
distribution.
➢ From developing methods that lower the cost of manufacturing silicon for solar panels to
designing more optimal ways to construct wind farms, mechanical engineers are critical to
lowering the cost of renewable energy infrastructure.

Department of Mechanical Engineering, MCE, Hassan 16

Introduction to Mechanical Engineering

Role of Mechanical Engineers in Energy Sector

Department of Mechanical Engineering, MCE, Hassan 17

Introduction to Mechanical Engineering

Manufacturing Sector
➢ Mechanical engineers in manufacturing works to bring the idea and designs into reality
by proper selection of material, machine, and manufacturing process.
➢ Involves right from the selection of materials and tooling, manufacturing, planning
process layouts, plant layouts, equipment specification, tool design, value analysis, cost
control, final assembly, inspection, packing, dispatch/shipment.

Department of Mechanical Engineering, MCE, Hassan 18

Introduction to Mechanical Engineering

Automotive Sector
➢ Mechanical engineers drive the automotive industry. From 80-seater buses to single seat
F1 cars, they design bodyshells, wheelsets and combustion systems for every type of
moving vehicle.
➢ Mechanical engineering in the automotive industry is key to developing new types of
vehicles, updating models, repairing existing vehicles and implementing new
functionalities and safety features.

Department of Mechanical Engineering, MCE, Hassan 19

Introduction to Mechanical Engineering

Aerospace Sector
➢ With the design, development, production and testing of aircraft, spacecraft, and related
equipment and systems.
➢ Evaluate designs to ensure products meet engineering principles, customer
requirements, and environmental challenges.
➢ Missiles or Rockets.

Department of Mechanical Engineering, MCE, Hassan 20

Introduction to Mechanical Engineering

Automation
➢ Engineers are responsible for the design, development and implementation of automated
systems that help manufacturing processes run efficiently.
➢ This includes the design and development of modular components that their team can
easily integrate into the manufacturing process.
➢ Develop or modify existing production or testing equipment to make it more efficient or
help implement new methods.

Department of Mechanical Engineering, MCE, Hassan 21

Introduction to Mechanical Engineering

Industry 4.0

➢ Mechanical engineers are working hand in hand with computers to make machines
communicate without human involvement keeping the possibility of developing a smart
factory.

➢ Industry 4.0, also known as the fourth industrial revolution, refers to the ongoing
transformation of traditional industries through the integration of advanced
technologies and digitalization.

➢ It is characterized by the convergence of physical systems with digital technologies,

enabling a new level of connectivity, automation, and data exchange in various sectors,
including manufacturing, logistics, healthcare, and more.

Department of Mechanical Engineering, MCE, Hassan 22

Introduction to Mechanical Engineering

Industry 4.0

Department of Mechanical Engineering, MCE, Hassan 23

Introduction to Mechanical Engineering

Industry 4.0

Department of Mechanical Engineering, MCE, Hassan 24

Introduction to Mechanical Engineering

Engineering Materials
• Engineering materials are defined as solid substances which are manufactured and used
for various engineering applications.
• There are various materials available and the choice of a particular material for a
specific application depends on the set of properties possessed by the materials.

Department of Mechanical Engineering, MCE, Hassan 25 25

Introduction to Mechanical Engineering

Metals and Their Alloys

• A metal is a material, an element, compound or alloy that is typically hard when in the
solid state, opaque and shiny
• Metals are generally malleable and ductile

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Introduction to Mechanical Engineering

Classification of Ferrous Metals

Pig Iron
• It is the first stage of iron directly extracted from the ore through blast furnace. It
Contain high percentage of carbon and other impurities.
• Properties: High hardness and Vey brittle
• Applications: It is used in making wrought iron, cast iron and steel

Department of Mechanical Engineering, MCE, Hassan 27

Introduction to Mechanical Engineering

Wrought iron
• Wrought iron is an iron alloy with a very low carbon content
• Properties: Low carbon content, Soft, Highly Ductile in nature, High toughness, Good
machinability, Corrosion resistance, High elasticity
• Applications: Due to corrosion resistance, it is used in making steam and water pipes.
Decorative applications like fences, gates and railings, balconies, bars, engine bolts,
rivets, railway couplings, chain links and crane hooks.

Department of Mechanical Engineering, MCE, Hassan 28

Introduction to Mechanical Engineering

Cast Iron
• Is a ferrous material that is produced when pig iron is remelted in a cupola furnace and
poured into mould in order to make castings
• Properties: Very strong but brittle, Low melting point, Good fluidity, Castability, Good
machinability, wear resistance
• Applications: Manufacture of machine frames, columns, beds and plates, housing,
flywheels, manhole covers, engine block, cylinder head, gearbox case, machine parts
etc.

Department of Mechanical Engineering, MCE, Hassan 29

Introduction to Mechanical Engineering

Grey Cast Iron

• It is produced when the molten pig iron in the mould is allowed to cool and solidify
slowly. Carbon here is mainly in the form of graphite.
• Properties: Good castability, High fluidity, easy Machinability, high strength and
ductility under compressive loads. It is named as Grey cast iron because of its freshly
fractured surface has a grey appearance.
• Applications: Base structures of machinery, Automotive engine blocks, gears,
flywheels, brake discs and drums and machine bases.
• Others – white and malleable cast iron

Department of Mechanical Engineering, MCE, Hassan 30

Introduction to Mechanical Engineering

Steel
• Steel is an alloy of iron and carbon with carbon content being less than 2% . In addition
various alloying elements like sulphur, phosphorous, manganese, nickel, chromium,
copper etc., in small proportions.
• Types: Carbon steel, alloy steel and tool steel
Carbon Steel
• Is a kind of steel in which the main alloying constituent is carbon in the range of 0.12-
2%.
• This tiny amount of carbon produces a material that exhibits great strength, hardness.
Other elements present in small proportions are sulphur, phosphorous, manganese and
magnesium
• It is classified as
• Low Carbon Steel
• Medium Carbon Steel
• High Carbon Steel

Department of Mechanical Engineering, MCE, Hassan 31

Introduction to Mechanical Engineering

Low Carbon Steel

• It is also called as Mild steel and the most common type of carbon steel. It contain 0.03-
0.25% off carbon and rest is iron
• Properties: It is soft, ductile and it has good machinability, good weldability, good
toughness, good impact resistance.
• Applications: It finds applications in nails, rivets, bolts, nuts, beams, boiler plates,
shafts, gears and axles.

Department of Mechanical Engineering, MCE, Hassan 32

Introduction to Mechanical Engineering

Medium Carbon Steel

• It has 0.25-0.59% of carbon and rest is iron.
• Properties: It has properties like good toughness, high hardness, high tensile strength,
good bending strength, wear resistance and good machinability.
• Applications: It is used in transmission shafts, axles, gears, connecting rods, couplings
and in spring manufacturing.

Department of Mechanical Engineering, MCE, Hassan 33

Introduction to Mechanical Engineering

High Carbon Steel

• It has 0.6 – 1.5% of carbon and rest iron.
• Properties: It has good strength and wear resistance, very ductile, low impact strength.
• Applications: It is used in hammers, Chisels, Screws, Punches, Hacksaw blades, Drills,
Leaf spring, ball bearings, milling s-cutters.

Department of Mechanical Engineering, MCE, Hassan 34

Introduction to Mechanical Engineering

Alloy Steel
• An alloy can be defined as a homogeneous mixture of two or more metals. Alloy steel
include iron and carbon.
• These steels are produced by adding other than carbon in calculated amounts in order to
provide specific properties.
• Principle alloying elements are chromium, nickel, manganese.
• Alloying elements are added for properties such as
• Improved machinability, weldability and castability Improved strength
and ductility Improved fatigue and corrosion resistance
• Common types of alloy steels are
• Chromium steel
• Nickel steel
• Manganese Steels

Department of Mechanical Engineering, MCE, Hassan 35

Introduction to Mechanical Engineering

Applications of stainless, chromium and nickel steel

Department of Mechanical Engineering, MCE, Hassan 36

Introduction to Mechanical Engineering

Classification of Non - Ferrous Metals

Aluminium
• It is one of the widely used metal in recent years, which has replaced iron and steel
because its special properties like light weight, non-corrosive, it is sivery white, soft,
ductile material.
• It is extracted from Bauxite
• The mechanical properties can be improved by mixing aluminium with silica, copper,
zinc
• Properties: Light weight, high ductility, good electrical and thermal conductivity, good
resistance to corrosion
• Applications: aircraft parts, automobile parts, cooking utensils, cables, induction
motors

Department of Mechanical Engineering, MCE, Hassan 37

Introduction to Mechanical Engineering

Alloys of Aluminium
• Duralumin - 92% Aluminium, 3.5-4.5 Copper, 0.4-0.7 % Magnesium, 0.4-7%
Manganese
• Magnalumin - 95% Aluminium, 5% Magnesium
• Yttrium-Alloy - 93% of aluminium, 4% copper, 2% nickel and 1% magnesium

Department of Mechanical Engineering, MCE, Hassan 38

Introduction to Mechanical Engineering

Copper
• Reddish brown colour, extracted from PYRITE
• Properties: It is soft, malleable, ductile, light weight, high thermal conductivity, good
corrosion resistance, good electrical and thermal conductivity
• Applications: door knobs, electrical wires, alloy of brass and bronze, tubes in
refrigerators and air conditioners
• Other – tin, lead, zinc and their alloys

Department of Mechanical Engineering, MCE, Hassan 39

Polymers
➢Polymers are materials that consist of molecules formed by long chains
of repeating units. They may be natural or synthetic.
➢Many useful engineering materials are polymers, such as plastics,
rubbers, fibers, adhesives, and coatings.
➢Polymers are classified as thermoplastic polymers, thermosetting
polymers (thermosets), and elastomers.

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Thermoplastic Polymers
➢Classification of thermoplastics and thermosets is based on their
response to heat.
➢If heat is applied to a thermoplastic, it will soften and melt. Once it is
cooled, it will return to solid form.
➢Thermoplastics do not experience any chemical change through
repeated heating and cooling (unless the temperature is high enough to
break the molecular bonds).
➢They are therefore very well suited to injection molding.

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Thermosetting Polymers
➢ Thermosets are typically heated during initial processing, after which they become
permanently hard.
➢ Thermosets will not melt upon reheating.
➢ If the applied heat becomes extreme however, the thermoset will degrade due to
breaking of the molecular bonds.
➢ Thermosets typically have greater hardness and strength than thermoplastics.

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Elastomers
➢ Elastomers are highly elastic polymers with mechanical properties similar to rubber.
➢ Elastomers are commonly used for seals, adhesives, hoses, belts, and other flexible
parts.
➢ The strength and stiffness of rubber can be increased through a process called
vulcanization, which involves adding sulfur and subjecting the material to high
temperature and pressure.
➢ This process causes cross-links to form between the polymer chains.

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Ceramics

➢ Ceramics are solid compounds that may consist of metallic or non-metallic elements.

➢ The primary classifications of ceramics include glass, cement, clay products, refractories, and
abrasives.

➢ Ceramics generally have excellent corrosion and wear resistance, high melting temperature, high
stiffness, and low electrical and thermal conductivity.

➢ Ceramics are also very brittle materials.

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Glass
➢ Glasses are common materials and are seen in applications including windows,
lenses, and containers. Glasses are amorphous, whereas the other ceramics are mainly
crystalline. Primary advantages of glasses include transparency and ease of
fabrication.
➢ The base element of most glasses is silica, and other components can be added to
modify its properties.

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Clay
➢ Clay is a very common ceramic material.
➢ It can be mixed with water, shaped, and then hardened through firing at high
temperature.
➢ The two primary classifications of clay products include structural clay products and
whitewares.
➢ Structural clay products see applications including bricks, tiles, and piping.
➢ White wares see applications including pottery and plumbing fixtures

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Refractories
➢ Refractory ceramics can withstand high temperatures and extreme environments.
➢ They can also provide thermal insulation.
➢ Brick is the most common refractory ceramic.

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Abrasives
➢ Abrasive ceramics are hard materials that are used to cut, grind, and wear away other
softer materials.
➢ Typical properties of abrasives include high hardness, wear resistance, and
temperature resistance.
➢ Abrasives can either be bonded to a surface (e.g. grinding wheels and sandpaper) or
can be used as loose grains (e.g. sandblasting).
➢ Common abrasives include cemented carbide, silicon carbide, tungsten carbide,
aluminum oxide, and silica sand.
➢ Diamond is also an excellent abrasive, but it is expensive.

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What are Composite Materials?
❖Composite material is a structural material that consists of two or
more combined constituents which are combined at macroscopic
level and are not soluble in each other.
❖One of its constituents is called the reinforcing phase and the other
one, in which the reinforcing phase material is embedded, is called
the matrix.
❖The reinforcing phase material may be in the form of fibers,
particles, or flakes (e.g. Glass fibers).
❖The matrix phase materials are generally continuous (e.g. Epoxy
resin).
❖The matrix phase is light but weak.
❖The reinforcing phase is strong and hard and may not be light in
weight.
Composites
➢A composite is a material in which one or more mutually insoluble
materials are mixed/bonded together.
➢The primary classes of composites are particulate composites, fibrous
composites, and laminated composites.

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Advantages of Composites
❑Composites are engineered materials. We can engineer them
specifically to meet our needs on a case‐to‐case basis.
❑In general, following properties can be improved by using composite
materials.
✓Strength
✓Modulus
✓Weight
✓Electrical conductivity
✓Thermal conductivity
✓ Fatigue
✓Behavior at extreme temps.
✓Acoustical insulation
✓Vibration damping
✓Aesthetics
✓Resistance to wear
✓Resistance to corrosion
Limitations of Composites

✓Costly
✓Difficult to fabricate
✓Sensitivity to temperature
✓Moisture effects
 Applications of Composites

Automotive industry: Lighter, stronger, wear resistance, rust‐free,

aesthetics
– Car body
– Brake pads
– Drive shafts
– Fuel tanks
– Hoods
– Spoilers
Aerospace: Lighter, stronger, temperature resistance, smart structures,
wear resistance
– Aircraft: Nose, doors, struts, trunnion, fairings, cowlings, ailerons,
outboard and inboard flaps, stabilizers, elevators, rudders, fin tips,
spoilers, edges
– Rockets & missiles: Nose, body, pressure tanks, frame, fuel tanks,
turbo‐motor stators, etc.
– Satellites: Antennae, frames, structural parts
Sports: Lighter, stronger, toughness, better aesthetics, higher damping
properties
– Tennis
– Bicycles
– Badminton
– Boats
– Hockey
– Golfing
– Motorcycles …
Transportation & Infrastructure: Lighter, stronger, toughness,
damping
– Railway coaches
– Bridges
– Ships and boats
– Dams
– Truck bodies and floors
– RV bodies
Other industry sectors
Biomedical industry
Consumer goods
Agricultural equipment
Heavy machinery
Computers
Healthcare