Syllabus - Materials Engineering and Solid Mechanics (EV405)

Electric Vehicles

Materials Engineering and Solid Mechanics (EV405)

IV

Module 1 Solidification of metals

Crystallisation, Crystal and amorphous, different types of bonds in different metals, Crystallography. Stability and metastability of metals. Different mechanical properties of metals and other engineering materials like strength, hardness, elasticity, plasticity, Malleability, Ductility, Creep, Fatigue etc. Introduction to industrial metals, steels and prevailing manufacturing methods by manufacturers.

Module 2 Cooling curves

Isomorphous, Utectic, Eutectoid, Eutectoid solid solution, Peritectic and other phase diagrams, Alloying, Characteristics of alloying elements, Iron – Carbon phase diagram, T-T-T diagrams, Types of Cast Iron. Types of Stainless Steels, Elastic, anelastic and Viscoelastic behavior.

Module 3 Heat treatment of metals

Based on phase diagram and T-T-T-Diagram the heat treatment of various metals, Bulk heat treatments, surface heat treatments, Case carburising, Types of Anealing, Normalizing, Spherodising, Phase Transformations like Parlite, Cementite, Austenite, Troostite, Bainite, Hard and soft Marten site etc. Laser hardening, Cyniding, Boriding, Nitriding, Flame hardening, Ion implantation, Etc. Heat treatment cycles. Metallographic studies, Optical Microscope, Electron Microscope.

Module 4 Stress and strain

stresses in members of a structure, axial loading, normal stress, shear stress, analysis of simple structures, stepped rods, members in series and parallel: stress strain diagram, Hooke’s law, stress due to temperature, Poisson’s ratio, Bulk modulus, shear strain, relation among elastic constants, residual stress, fiber reinforced composite materials, strain energy under axial loads and stresses due to impact of falling weights. Transformation of stress and strain, principal stresses, normal and shear stress, Mohr’s circle and its application to two and three dimensional analysis.

Module 5 Bending of Beams and Torsion of Shafts

pure bending, symmetric member, deformation and stress, bending of composite sections, eccentric axial loading, shear force and BM diagram, relationship among load, shear and BM, shear stresses in beams, strain energy in bending, deflection of beams, equation of elastic curve, Macaulay’s method and Area moment method for deflection of beams. Torsion in shafts: Tensional stresses in a shafts, deformation in circular shaft, angle of twist, stepped and hollow transmission shafts, Theories of Failures.

Course Objective

To understand the basics of solidification of metals, bonds in different metals and different mechanical properties of engineering materials. To learn about cooling curves, phase diagrams and Iron carbon diagram. To compare the application of various heat treatment processes. Know the concepts of stress and strain. Analyze the beam of different cross sections for shear force, bending moment, slope and deflection.

Practicals

  • Metallographic studies

    Study of Optical microscope, Optically flat surface preparation, etching reagents, Grain size- ASME no., micro structures, Image analysis, Standard specimen

  • Carbon, sulphur, Phosphorus determination

    Strauhlin’s apparatus, Eggert’s Method in different samples.

  • Hardness and Hardenability test

    Jeremy Cony test. Soft and hard Martensite.

  • Different heat treatment cycles using electric furnace [ Programmable preferred ], Annealing, Case carburising, Normalising, etc

  • Standard tensile test on MS and CI test specimen with the help of UTM

  • Direct/ cross Shear test on MS and CI specimen

  • Transverse bending test on wooden beams to obtain modulus of rupture

  • Fatigue test 5. Brinell Hardness tests 6. Vicker hardness test

  • Izod/Charpy test 8 Rockwell Hardness test

Reference Books

  • V. Raghwan, Material Science.

  • G.E.Dieter, Mechanical Metallurgy.

  • P Chalmers, Physical Metallurgy.

  • R. C.Rollason, Metallurgy for mechanical engineers.

  • Khanna O.P. Materials Science.

  • Sadhu Singh; Strength of Materials; Khanna Pub.

  • R Subramannian , Strength of materials OXFORD University Press ,Third Edition

  • S Ramamurthum , Strength of materials , Dhanpat Rai