Certificate in Mechanical Engineering

COURSE OBJECTIVES:

By the end of this course you will be able to:

 

• Understand basic mechanical engineering concepts such as force, work, power, moments and torques
• Identify the various balanced and unbalanced forces and loads in a system
• Determine the importance of common engineering material properties in relation to component life and failure
• Perform basic design for static strength
• Apply the theory and principles governing the operation of common mechanical drive components
• Select appropriate gears and bearings
• Understand the underlying principles governing the operation of common mechanical prime movers and actuators
• Distinguish between the various heat transfer mechanisms and understand the principles governing the design of heat-exchangers
• Perform simple design and selection of piping systems and related components
• Monitor, control and analyze vibrations
• Select the appropriate manufacturing system and understand the principles of design for manufacturing
• Initiate and set up an effective but simple inspection and maintenance program (including lubrication)
• Appreciate the need for standardization and understand the common applicable mechanical standards and codes

OVERVIEW

Mechanical engineering in simple terms deals with any equipment that moves; this is what makes it perhaps the most broad and diverse of engineering disciplines. The mechanical discipline essentially derives its breadth from the need to design and manufacture everything from small, even nano, individual devices, such as measuring instruments, to large systems such as machine tools and power plants. Easy installation and serviceability are critical to the success of a mechanical system as is operational and design flexibility. Understanding parameters governing the selection and design of mechanical systems is essential for identifying suitable systems for a particular application.

In order to place all these issues in context, a good working knowledge of mechanical principles combined with a solid understanding of key concepts such as force, energy and heat is important. Mechanical power transmission is discussed from the point of view of gears, couplings and bearings. Proper selection and sizing of these critical mechanical components is vital to ensuring optimum performance and improved efficiency of a mechanical system. Recently, fluid engineering has undergone significant change and therefore a detailed overview of the underlying principles of fluid power and its applications is vital. The theory behind heat transfer, the various heat transfer mechanisms and the design of heat exchangers is also examined.

Any study of mechanical systems would be incomplete without including a review of mechanical vibrations. This will help you in monitoring, controlling and analyzing vibrations and in conducting fault diagnoses in mechanical systems. The field of maintenance has evolved into a separate and highly specialized function. An effective maintenance regime helps identify failure symptoms and enables initiation of corrective measures, for preventing unscheduled and sometimes catastrophic failures. Lastly, a discussion on the numerous standards, codes and regulations governing mechanical systems, helps put the whole course into perspective.

COURSE OUTLINE:

UNIT 1: Mechanical Engineering Basics

Introduction and basic concepts
Units for engineering quantities
Interpretation of mechanical drawings
Friction - importance in mechanical systems, types, static and dynamic friction coefficients

UNIT 2: Engineering Materials

Stress - strain relationship
Properties of engineering materials: strength, hardness, ductility and toughness
Thermal processing of metals and how it affects their properties
Ferrous and non-ferrous alloys
Common failure of modes of materials: Fracture, fatigue, creep and corrosion

UNIT 3: Mechanical Design

Basic principles
Factor of safety
Static equilibrium
Design for static strength
Threaded fasteners
Keys and keyways
Riveted joints
Design for fatigue strength

UNIT 4: Gears and Bearings
 

Gears: Terminologies, types, ratios and gear trains
Gear selection and gearboxes
Troubleshooting gear problems
Bearings: Loads, types, selection and troubleshooting
Installation guidelines

UNIT 5: Mechanical Drives

Belt and chain drives
Mechanical couplings
Hydrostatic drives
Hydrodynamic drives
Torque converters and fluid couplings
Clutches: Types, performance and selection
Brakes: Types, performance and selection

UNIT 6: Prime Movers

What is a prime mover?
Internal combustion engines
Electric motors
Hydraulic and air motors
Gas turbines
Mechanical variable speed drives
Hydraulic and pneumatic cylinders
Comparative merits/demerits of different prime movers
Primer mover selection criteria, applications

UNIT 7: Fluid Engineering

Concepts: Viscous flow and Reynolds number
Piping, selection and sizing
Pumps and valves: Types and applications
Fluid engineering symbols and diagrams
Analysis of piping systems
Seals, fittings, flanges gaskets and O-rings
Mechanical seals: Types, selection and Maintenance

UNIT 8: Theory of Heat Transfer

Laws of thermodynamics
Thermal cycles
Heat exchangers: Types, maintenance and troubleshooting
Heat pumps
Air conditioning
Heat: Conduction, convection and radiation

UNIT 9: Mechanical Vibrations

Single degree of freedom system
Terminologies: Amplitude, phase and frequency
Natural frequency of vibration
Multiple degree of freedom system
Vibration measurement: sensors, analysers and interpretation
Use of vibration as a condition monitoring tool
Troubleshooting and correcting unwanted Vibrations
 

UNIT 10: Manufacturing and Production Systems

Metal production - foundry process
Cast making and metal melting
Die and precision casting
Heat treatment (hardening and softening)
Hot and cold working of metal
Presses
Numerical control
Machining and metal cutting
Broaching, shaping and sawing
Basics of welding and types of welded joints
Brazing
CAD/CAM
Rapid prototyping
 

UNIT 11: Maintenance

Objectives, reliability and availability
Breakdown, preventive and predictive maintenance
Standard practices and tools
Lubrication
Factors influencing equipment downtime
Hazardous failures
Condition monitoring methods
Non-destructive testing and inspections
Planning and inspection schedules

UNIT 12: Mechanical Engineering Codes and Standards

Need for standardization
Mechanical engineering standards
Overview of standards
Benefits of standardization
ISO 9000/1
Six-sigma