Mechanical Engineering Department

Semester 1: Dissection of mountain bicycle and Engineering Design challenge

During the first semester the students have little or no knowledge of engineering, so the students dissect and explore a bicycle and use the newly acquired knowledge to conceptualize a new design of bicycle. In this engagement students, in groups, are given bicycle for disassembly and reassembly. They take apart the bike axle (back, front or crank), handle bar assembly and the rear suspension. In later part of EL day, they develop a concept and make sketches or drawings of a special needs bicycle.

Faculty Facilitator

Dr. Ravinder Singh Joshi
Dr. Ravinder Kumar Duvedi

The basic outline of the activity is:

 Step-by-Step Disassembly:

• Start by removing the wheels from the bicycle. Use a wrench to loosen the bolts or quick-release levers that hold the wheels in place.
• Next, remove the pedals from the crank arms. This may require a pedal wrench.
• Proceed to remove the chain from the bicycle.
• Remove the seat and seat post from the frame.
• Remove the handlebars and stem from the fork.
• Continue disassembling other components such as the brakes, derailleurs, and crank set.
• As you remove each part, take the opportunity to explain its function and how it contributes to the overall operation of the bicycle.

Observation and Discussion:

As each component is removed, each participant observe closely and discuss what they see. Prompt questions about the materials, mechanisms, and interactions between parts. Discuss concepts such as friction, leverage, and mechanical advantage.

• Reassembly: To reassemble the bicycle after the dissection is complete. This provides an opportunity to reinforce the understanding gained during the disassembly process.
• Reflection: Conclude the activity with a discussion or reflection session where participants share what they learned from the dissection process. Encourage them to relate their observations to real-world applications or other areas of study.

Semester 2: Dissection of internal combustion engine and automobile transmission

In this activity students get to dissect and reassemble a portable internal combustion engine and automobile gearbox. Students learn about materials, parts and their functions, mechanics, thermodynamics, electronics involved and several other concepts related to operation of I.C Engine. The activity day ends with a reflection session where the students discuss their observations with each other and expert faculty. The students form groups and solve design challenge under the guidance of faculty with specialization in related areas of engineering.

Faculty Facilitator

Dr. Devender Kumar
Dr. Sumit Sharma

The basic outline of the activity is:

 Identify Tools: Gather the necessary tools for disassembly, such as wrenches, screwdrivers, pliers, and lubricants.

Step-by-Step Disassembly:

• Start by disconnecting any external components such as the air filter, exhaust system, and fuel lines.
• Use wrenches and sockets to remove the bolts securing the engine's components, such as the cylinder head, valve cover, and oil pan.
• Carefully remove these components, taking note of their positions and orientations.
• As each component is removed, discuss its function and importance in the operation of the engine. Explain concepts such as combustion, compression, and exhaust.
• Use diagrams or models to illustrate the internal components of the engine, such as pistons, connecting rods, crankshaft, camshaft, valves, and cylinder walls.
• If feasible, disassemble further to reveal internal components such as piston rings, bearings, and timing mechanisms.

Observation and Discussion:

• Encourage participants to closely observe the components as they are removed. Discuss the function of each part and how they work together to convert fuel into mechanical energy. Address questions about the operation, efficiency, and design of internal combustion engines.

Reassembly:

• To reassemble the engine after the dissection is complete. This provides an opportunity for participants to understand the assembly process and the importance of proper alignment and torque specifications.

Reflection:

• Conclude the activity with a discussion or reflection session where participants share what they learned from the dissection process. Encourage them to relate their observations to real-world applications, such as automotive design and maintenance, or environmental impacts.

Semester 3: Design of a pneumatically actuated chair testing machine

The goal of this activity is to expose the students to use of pre-engineered parts to prototype machine quickly and economically. In this machine design thread with pre-engineered components, students learn about machine structures and pneumatic systems. In the process they learn about data sheets and part selection and fabricate the pneumatic system of a chair testing machine. They learn about collection of testing data from the machine, use it for development of furniture testing machine.

Faculty Facilitators

Dr. Anant Kumar Singh

Dr. Ashish Singla

The basic outline of the activity is:

 Introduction to Pneumatics and Chair Design: Start by introducing participants to the basics of pneumatics, including the principles of air pressure, pneumatic components (such as cylinders, valves, and actuators), and their applications in engineering. Explain the concept of a pneumatically actuated chair and its potential benefits, such as adjustable height or reclining features.

Brainstorming and Design Phase:

• Divide participants into teams and task each team with designing a pneumatically actuated chair. Provide them with design constraints, such as size limitations, weight capacity, and safety considerations.
• Encourage teams to brainstorm ideas, sketch their designs, and consider factors such as ergonomics, comfort, and ease of use.
• Have teams create detailed design plans, including CAD drawings if possible, outlining the components, dimensions, and assembly process of their chairs.

Material Acquisition and Construction:

• Provide participants with materials and components needed to build their chairs, such as pneumatic cylinders, valves, tubing, fittings, and a sturdy chair frame.
• Allow teams time to construct their chairs according to their design plans. Offer guidance and assistance as needed, particularly with pneumatic system assembly and integration.

Testing Phase:

• Once the chairs are constructed, move on to the testing phase.
• Adjustability: Test the chair's ability to change height or recline smoothly and accurately.
• Stability: Assess the chair's stability and resistance to tipping or wobbling, particularly when adjusting positions.
• Load Capacity: Test the chair's ability to support different weights and loads.
• Durability: Subject the chair to repeated cycles of actuation to evaluate its long-term reliability.
• Gather data during testing, such as measurements of chair height, angles, and forces exerted, as well as observations of any issues or failures encountered.

Analysis and Iteration:

• After testing, gather teams to analyze the results and discuss the performance of their chairs.
• Encourage teams to identify areas for improvement and brainstorm possible design modifications or enhancements.
• Allow teams time to iterate on their designs, make adjustments, and implement improvements based on the testing feedback.
• Facilitate a group discussion where participants reflect on the challenges, successes, and insights gained from the activity. Encourage them to consider how principles of pneumatics and chair design can be applied to real-world engineering projects.

Semester 4: Design and testing of a CNC machine tool drive and control system

The students are given a working CNC machine and they are expected to take apart all the components and reassemble the machine. In this machine design thread with pre-engineered components students learn about linear motion elements, pulleys, screws, belts and actuators. This also facilitates the understanding of principles behind computer-controlled machines and its programming. They are asked to design a pen plotter considering loads, constraints and manufacturability of the components.

Faculty Facilitator

Dr. Vivek Jain

Dr. Deepak Jain

The basic outline of the activity is:

Introduction to CNC Machines: Start by introducing participants to the concept of CNC machining and its applications in various industries, such as manufacturing, prototyping, and woodworking. Explain how CNC machines use computer-controlled motors to precisely cut, carve, or shape materials based on digital designs.

Brainstorming and Design Phase:

• Divide participants into teams and task each team with designing a CNC machine for a specific application, such as milling, engraving, or 3D printing.
• Provide teams with design constraints, including size limitations, material compatibility, and budget considerations.
• Encourage teams to brainstorm ideas, sketch their designs, and consider factors such as machine rigidity, precision, speed, and ease of use.
• Have teams create detailed design plans, including CAD drawings or 3D models, outlining the components, dimensions, and assembly process of their CNC machines.
• Provide participants with materials and components needed to build their CNC machines, such as linear motion rails, stepper motors, lead screws, bearings, electronics, and a sturdy frame.
• Allow teams time to construct their machines according to their design plans. Offer guidance and assistance as needed, particularly with assembly and wiring of electronic components.
• Guide participants through the process of programming their CNC machines, including setting up work coordinates, specifying cutting parameters, and generating tool paths for their chosen applications.
• Assist teams in calibrating their machines to ensure accurate positioning, motion control, and tool alignment. Conduct test runs with simple geometric shapes to verify the machine's performance and identify any issues or errors.

Testing and Optimization:

• Teams conduct more comprehensive machining tests with their CNC machines. Provide a variety of materials for testing, such as wood, plastic, or aluminum, depending on the machine's intended application.
• Develop a testing protocol that evaluates key performance metrics, such as cutting accuracy, surface finish, repeatability, and throughput.
• Encourage teams to iterate on their designs and machining parameters based on testing results, making adjustments to improve performance, efficiency, and reliability.

Facilitate a group discussion where participants reflect on the challenges, successes, and lessons learned from the activity. Encourage them to consider how CNC technology can be applied to real-world manufacturing processes and innovation.

Semester 5: Design and testing of a custom plate type heat exchangertem

The objective of this activity is to expose students to the basics of the heat exchangers, concepts, materials, temperature and flow measurement techniques, etc. Students learn computational fluid dynamics, importance of controllable parameters, overall dimensions, and fabrication of a plate type heat exchanger.

Faculty Facilitator

Dr. Vikrant Khullar

Dr. Sayan Sadhu

The basic outline of the activity is:

• Start by introducing participants to the concept of custom plates and their applications. Explain that custom plates are flat structures typically used for mounting or supporting other components in various engineering projects. Examples include mounting plates for machinery, brackets for structural support, or base plates for equipment.
• Define the purpose of the custom plate. Is it for mounting specific equipment, providing structural support, or serving as a base for a project?
• Discuss the requirements for the custom plate, such as size, shape, material, weight capacity, and environmental factors (e.g., temperature, moisture).
• Encourage participants to consider any constraints or limitations, such as cost, manufacturing capabilities, and safety standards.

Brainstorming and Design Phase:

• Divide participants into teams and task each team with designing a custom plate for a given scenario or application.
• Provide teams with design constraints and requirements based on the identified purpose.
• Encourage teams to brainstorm ideas, sketch their designs, and consider factors such as geometry, material selection, load distribution, and manufacturing feasibility.
• Have teams create detailed design plans, including CAD drawings or sketches, specifying dimensions, tolerances, and any necessary features (e.g., holes, slots, mounting points).

Fabrication and Assembly:

• Allow teams time to fabricate their custom plates according to their design plans. This may involve cutting, bending, welding, or machining processes, depending on the chosen material and design.
• Provide guidance and assistance as needed, particularly with fabrication techniques and safety precautions.
• Ensure that teams properly assemble their custom plates, including any additional components or hardware required for mounting or installation.

Testing and Evaluation:

• Develop a testing protocol to evaluate the performance of the custom plates. This may include structural tests, such as load testing, bending tests, or vibration tests, depending on the intended application.
• Conduct tests using appropriate equipment and procedures, ensuring safety precautions are followed at all times.
• Gather data during testing, such as load capacity, deflection, and any signs of failure or deformation.
• Encourage teams to analyze the test results and identify any areas for improvement or optimization in their custom plate designs.

Facilitate a group discussion where participants reflect on the challenges, successes, and insights gained from the activity. Encourage them to consider how principles of custom plate design can be applied to real-world engineering projects and problem-solving.