DIPLOMA IN CERAMIC TECHNOLAGY

DIPLOMA IN CERAMIC TECHNOLAGY
3 ½ YEAR SANDWICH COURSE (UNDER MPEC SYSTEM)
FIRST SEMESTER

Subject
Name of the Subject
Instruction Periods/Week
Total Periods/ Semester

Scheme Of Examinations
Theory
Practicals
Duration
(hrs)
Sessional Marks
End Exam Marks

Total Marks
Credits

THEORY SUBJECTS
CER-1101
English -I
3
-
45
3
20
80

100
3
CER-1102
Engineering Mathematics – I
5
-
75
3
20
80

100
5
CER-1103
Engineering Physics-I
4
-
60
3
20
80

100
4
CER-1104
Engineering Chemistry & Environmental Studies -I
4
-
60
3
20
80

100
4

CER-1201
Elements of Ceramic Technology -I
4
-
60
3
20
80

100
4
CER-1202
 Ceramic Raw Materials
5

75
3
20
80

100
5

PRACTICAL SUBJECTS

CER-1105

 

1105-A Physics Laboratory-I
-
03
45

3

20
30

50

1.5

1105-B Chemistry Laboratory-I

-
20
30

50
CER-1106
Engineering Drawing-I
-
06
90
3
40
60

100
4
CER-1203
Computer Fundamental Practice- I
-
04
60
3
40
60

100
2
CER-1301
Fundamental Properties of Ceramics Lab

-
04
60
3
40
60

100
2

Total
25
17
630
-
280
720

1000
34.5

ELEMENTS OF CERAMIC TECHNOLOGY-I


Subject Name                            : Elements of Ceramic TECHNOLOGY-i
SUBJECT CODE                             : CER-1201
periods/ Week                           : 04
PERIODS / SEMESTER                 : 60
TIME SCHEDULE                      

S.No
Major Topic
No. of Periods
Weightage of Marks
No. of Short Questions
No. of Essay Questions
1
Introduction
10
16
02
01
2
Types of Clay Ware /  Pottery Ware
12
16
02
01
3
Preparation of Clay  Bodies
12
26
02
02
4
Fabrication methods in Clay Industry
12
23
01
02
5
Finishing and Drying of Clay Ware
05
13
01
01
6
Glazing and Decoration
04
03
01
--
7
Firing of Ceramic Ware
05
13
01
01

Total
60
110
10
08

OBJECTIVES: 

On completion of the course the student should be able to know the following:
1.0   INTRODUCTION
1.1   Know the Origin of Ceramics.
1.2   Definition of Ceramics.
1.3   Discuss the Stages in the Development of Ceramics.
1.4   Understand the applications of the Ceramics.
1.5   List the Sub-branches in Ceramics.
1.6   Define the term Refractories with examples.
1.7   Define Glass and give examples.
1.8   List the Pottery ware and give examples.
1.9   Define Enamel and give examples.
1.10 Define Cement and give examples.
1.11 Know the importance of Silicate Technology in Ceramics.
2.0 TYPES OF CLAY WARE / POTTERY WARE
2.1 Define the terms Clay and Pottery.
2.2 Know the Porous bodies.
2.3 List the types of porous bodies and its properties.
2.4 List the Heavy Clay Ware products.
2.5 Define Terracotta.
2.6 Define Majolica Ware.
2.7 Define Earthen Ware.
2.8 Definition of Non-porous/Dense bodies.
2.9 List the types of Non-porous/ Dense bodies.
2.10 Define Stoneware.
2.11 Define Porcelain.
2.12 Define Bone China.
2.13 Know the Properties of Non-porous/Dense bodies.
2.14 Define the term White ware.
2.15 List the Types of product comes under White Ware.
2.16 List the Types of products comes under Vitreous and Semi Vitreous bodies
2.17 Define term Blue Pottery
2.18 Define the term Studio Pottery

3.0   PREPARATION OF CLAY BODIES
3.1   Know the Benification process of Plastic Materials (Clays) and Non-plastic Materials.
3.2   Know the Calcination and the use of calcination.
3.3   Know the stages in the body preparation.
3.4   Describe the crushing of Raw materials.
3.5   Describe the grinding of Raw materials.
3.6   Know the necessity of weighing of the batch.
3.7   Know the Importance of mixing of Raw materials.
3.8   Know the Tempering of Raw materials.
3.9   Know Blunging.
3.10 Know Agitation and Agitator.
3.11 Know Screening (or) Lawn.
3.12 Know Magnetic Separation process
3.13 Know the Spray drying process.
3.14 Know Filter pressing process.
3.15 Understand the term Ageing and Souring.
3.16 Know Pugging and De-airing.

4.0   FORMING METHODS IN CLAY INDUSTRY
4.1   List the types of Fabrication methods.
4.2  Know briefly the Slip casting processes like Solid Casting, Hallow Casting,    
         Pressure Casting, Battery Casting, etc.
4.3   Know the Plastic Forming.
4.4   Know the Soft mud processes like Hand moldings, Throwing,                                       
         Jiggering and Jollying, Ram press, etc.
4.5   Know the stiff mud process like extrusion, wire cut process etc.
4.6   Know the Turning process.
4.7   Know the Dry Pressing.

5.0   FINISHING AND DRYING OF CERAMIC WARE
5.1   Know the necessity of Finishing.
5.2   Know the Trimming process.
5.3   Know the Sponging process
5.4   Know the Fettling process.
5.5   Know the Towing process.
5.6   Know the necessity of drying.
5.7   Know the list of drying defects in Clay ware.
5.8   List the Types of dryers used in Ceramic industry.

6.0    GLAZING AND DECORATION
6.1    Define the term Glaze.
6.2    Classify the glazes according to Composition and Temperature   
6.3    List the Application methods of glaze.
6.4    Write the need of decoration of Ceramic Ware.
6.5    List the Ceramic coloring oxides.
6.6    Name the different Ceramic Stains.
6.7    Name the application methods of decoration.
6.8    Understand the under- glaze and on-glaze decoration process
6.9    List the defects in glazed ware.

7.0    FIRING OF CERAMIC WARE
7.1    Name the types of Kilns used for firing of ceramic ware
7.2    Know about Bisque Firing process.
7.3    Know about Glost Firing process.
7.4    Explain the action of Heat on clay bodies.
7.5    Understand the Physical & Chemical changes in the ceramic ware.

COURSE CONTENTS:

1. INTRODUCTION: Origin of Ceramics, Definition of Ceramics, Development of Ceramics, Importance of   Ceramics, Sub-branches in Ceramics, Silicate Technology related to Ceramics.
2.TYPES OF CLAY/POTTERY WARE: Definition of Pottery, Types of Pottery, Porous and Non-porous Bodies, Vitreous and Semi-Vitreous bodies, Blue Pottery, Studio pottery .
3.PREPARATION OF CLAY BODIES: Treatment of Plastic Materials. Treatment of Non-plastic materials. Body Preparation.

4.FORMING METHODS IN CLAY INDUSTRY: Types of Fabrication methods. Types of Slip Casting methods.   Types of Plastic Forming methods. Turning Process. Dry Pressing Process.
5.FINISHING AND DRYING OF CERAMIC WARE: Types of Finishing methods. Need of Drying, Types of Dryers.
6.GLAZING AND DECORATION: Definition of glaze, Types of glazes.  Preparation of glazes.  Methods of application of glaze. Need of decoration. Application methods of decoration. Ceramic colors. Ceramic stains.
7.FIRING OF CERAMIC WARE:            Types of Kilns, Bisque Firing. Glost Firing. Action of Heat on clay ware during firing.

Note: - The faculty, teaching the subject are requested to keep it in view that these topics are taught in detail as an individual papers in the future semesters, hence stress is to be given on the basics and flow charts .

REFERENCE BOOKS:

1. Sudhir Sen, Ceramic White Wares, Oxford & IBH publishing Ltd., New Delhi, 1992.
2. S.Kumar, Hand Book of Ceramics, Volume I and II. Kumar and Associates, Kolkata, 1994 and 1995
3. F.H.Norton, Elements of Ceramics, 2nd edition, Addison Wesley, London, 1994.
4. S.Kumar, Source of Ceramics, Dipankar Kumar, Kolkata, 2002
5. Saikat Maitra and Asis K Bandyopadhyay, Gate Way to Ceramics, SMD Udyog, 9/4A/1Q South Sinthee Road, Kolkata-5, 2003.
6. Felix Singer and Sonja S Singer Industrial Ceramics, Oxford & IBH Publishing Co., New Delhi, 1991.
7. Budnikov, P.P, The Technology of Ceramics and Refractories, Cambridge MIT, 1964.
8. R.Charan, Hand Book of Glass Technology,
9. Fay V. Tooley, Handbook of Glass Manufacture Volume I & II, Ogden Publishing Company, New York, 1960.
10. Samuel R Scholes, Modern Glass Practice, Industrial Publications, Inc., Chicago, 1952.
11. Handbook of Pottery, H.N Bose

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CERAMIC RAW MATERIALS

Nameof the Subject      :       Ceramic Raw Materials
Subject Code                     :       CER - 1202
Periods / Week                  :       05
Periods/ Semester          :       75

TIME SCHEDULE

S.No
Major Topic
No. of Periods
Weightage of Marks
No. of Short Questions
No. of Essay Questions
1
Elementary Geology
15
29
03
02
2
Descriptive Mineralogy
15
19
03
01
3
Major Ceramic Raw Materials
40
59
03
05
4
Man Made Materials
05
03
01
--

Total
75
110
10
08

OBJECTIVES:  On completion of the course, the student should be able to know the following:

1.0    ELEMENTARY GEOLOGY:
1.1    Define the term Geology, Petrology
1.2    Explain the formation of rocks
1.3    Write the characteristics of rocks
1.4    Classify the rocks
1.5    Know the Sub classification of rocks
1.6    Differentiate the Magma and Lava
1.7    Explain the formation of Intrusive rock and Extrusive rocks
1.8    Know the Sedimentary rock formation
1.9    Know the Metamorphism

2.0   DESCRIPTIVE MINERALOGY:
2.1   Define the term Mineral
2.2   Define the term Mineralogy
2.3   List the types of Minerals used in Ceramic industry
2.4   Define the term Ore
2.5   List the types of Ores used in Ceramic industry
2.6   Differentiate the Ore and a Mineral
2.7   Know the chemical composition of Minerals.
2.8   Know the physical properties of minerals.
2.9   List the major rock forming minerals for ceramics.
2.10 Write the minerals used in ceramics with the help of physical properties.
2.11 Know Magnetism
2.12 Know Optical Mineralogy

3.0 MAJOR CERAMIC RAW MATERIALS:
3.1 CLAYS:              
3.1.1    Know the types of Clay minerals as natural raw material like kaoline group, Montmorillonite group and Illite group.
3.1.2    Write the Origin of clays.
3.1.3   Understand the term kaolinization.
3.1.4   Classification of Clays.
3.1.5   Define the terms primary, secondary and fusible clays with examples.
3.1.6   Classify the Kaoline.
3.1.7   Know the Properties and uses of Kaoline.
3.1.8   Know the Properties and uses of Pyrophyllite.
3.1.9   Write the Impurities and its effects in clays.
3.1.10 List the Physical properties of clays.
3.1.11 Know  the occurrence, physical, chemical properties and uses in ceramics of the   following: -
            a. Fire clay.
            b. Grog.
            c. Flint fire clay.
            d. Marls
            e. Ball clay.
            f. Bentonite
            g. Shales, Loams. Loes etc.
            h. Low Vitrified Clays.
3.2 SILICA MINERALS:
3.2.1  Classify the Silica minerals
3.2.2  Know the occurrence, physical, chemical properties and uses in ceramic of the   following materials: -
           a. Quartz
      b. Quartzite
      c. Flint
      d. Diatomite
      e. Quartz sand.
      f. Glass sand
3.2.3 Know the Polymorphic modifications of quartz / Effect of heat on Quartz
3.3    ALUMINA MINERALS
3.3.1 Classify the Alumina minerals.
3.3.2 Know the the occurrence, physical, chemical properties and uses in ceramics of the   following : -
            a. Alumina minerals-Corundum
b. Hydrated Alumina minerals.
   (i). Bauxite, (ii). Gibbsite, (iii) Diaspore, (iv). Boehmite etc.
c. Alumino - Silicate minerals.
   (i). Sillimanite, (ii) Kyanite, (iii) Andalusite etc.,
            d. Hydrated Alumino Silicates.
            e. Alkali Alumino silicates:  (i). Feldspar, (ii). Talc, (iii). Beryl etc.

3.4       FELDSPAR GROUP MINERALS
3.4.1 Classify the Feldspar based on Mineralogical formula.
3.4.2  Classify the feldspar by chemical formula..
3.4.3  Know the Properties and uses of all varieties of Feldspars.
3.4.4  Know the Properties and uses of Nepheline and Nepheline syenite
3.4.5  Know the Occurrence, properties and uses of China stone/Cornish stone.

3.5       CARBONATE MINERALS:
3.5.1  List the carbonate minerals.
3.5.2 Know the Occurrence, properties and uses of Limestone, Dolomite, Magnesite, and Calcite.
3.5.3  Know the Occurrence, Properties and uses of Wollastonite.

3.6       MAGNESIUM SILICATE MINERALS:
3.6.1  List the Magnesium silicates.
3.6.2  Know the Occurrence, properties and uses of Steatite, Talc, Cordierite, and Forsterite
3.6.3 Know the Occurrence, properties and uses of Olivine, Fayalite,

3.7       FLUORINE MINERALS:
3.7.1  List the Fluorine minerals.
3.7.2  Know the Occurrence, properties and uses of Fluorspar and Cryolite

3.8    TITANIUM MINERALS:
3.8.1  List the Titanium Minerals.
3.8.2  Know the Occurrence, properties and uses of Rutile, Brookite. Anatase etc.,

3.9    BERYL
3.9.1    Know the Occurrence, properties and uses of Beryl
3.10     ZIRCONIA MINERALS
3.10.1 Know the Occurrence, properties and uses of Zircon, Zirconia and Beach  Sand.

3.11RARE EARTH MINERALS
3.11.1    List the Rare Earth minerals.
3.11.2    Know the occurrence, properties and uses of Rare earth minerals.

3.12.GYPSUM:
3.12.1 List the types of Gypsum
3.12.2 Know the Occurrence, properties and uses of Gypsum
3.12.3 Write the effect of Heat on gypsum
3.12.4 Explain the Preparation of plaster of Paris
3.12.5 List the Types of Plaster of Paris
3.12.6 Know the Properties and uses of Plaster of Paris

3.13. PYROXENE
3.13.1 Know the Occurrence, Properties and uses of Pyroxene

3.14 BARITES
3.14.1 Know the Occurrence, Properties and uses of Barites

3.15 GRAPHITE 
3.15.1 Know the Occurrence, Properties and uses of Graphite

3.16 LEAD
3.16.1 Know the Occurrence, Properties and uses of Read lead.
3.16.2 Know the Occurrence, Properties and uses of white lead

3.17 CHROMITE
3.17.1 Know the Occurrence, Properties and uses of Chromite.

4.0     MAN MADE MATERIALS
          Identify the occurrence and use of the following:
4.1    Understand the term Man made materials or Byproducts.
4.1     Blast Furnace Slag.
4.2     Fly ash and Paddy Husk ash.
4.3     Bone ash.
4.4     Phospho – gypsum
4.5     Red mud
COURSE CONTENTS:
1.ELEMENTARY Geology: Formation, characteristics, classification, Sub-classification of Rocks.  Formation of mineral deposits.  Relation of mineral deposits to igneous activity.  Magma, lava, crystallization, metamorphic process, sedimentary process of mineral formation.
2.DESCRIPTIVE Mineralogy: Chemical composition, Physical properties like color, streak, luster, cleavage, hardness, Crystalline, form, specific gravity, etc and major rock forming minerals for ceramics., magnetism and Optical mineralogy
3.Major Ceramic Raw Materials: Natural Raw Materials, Occurrence, availability, physical and chemical properties of natural minerals of clays, Synthetic materials etc.,
4.Man Made Materials: Blast furnace slag, Fly ash, Paddy husk ash, Bone ash, Phospho gypsum etc.,

REFERENCE BOOKS:

1. C D Gribble, Rutley’s Elements of Mineralogy, 27th Edition, Satish Kumar Jain for CBS Publishers, New Delhi, 1991.
2. Krishnan M.S, Introduction to Geology of India, The Madras Law Journal, 1943.
3. Kumar.S. , Handbook of Ceramics. Volume I , Kumar and Associate, Kolkata, 1994,
4. Worral, W.E. Clays and Ceramic Raw Materials, Pergaman press, New York, 1992.
5. W.Ryan, Properties of Ceramic Raw Materials, Pergaman press, New York, 1978.
6. A.V. Milovsker and O V Kononov, Mineralogy, Mir Publishers, Mascow, 1985.
7. DANA, E.S. Text book of Mineralogy, 1946
8. Norton FH, Fine Ceramics, Mec Graw Hill, New York, 1992.
9. Directory of Ceramic Raw materials, Indian Institute of Ceramics, Kolkata

-oOo-







FUNDAMENTAL PROPERTIES OF CERAMICS LAB

SUBJECT                                   :     FUNDAMENTAL PROPERTIES OF CERAMICS LAB

SUBJECT CODE                      :      CER- 1301
PERIODS/ WEEK                    :      4
PERIODS / SEMESTER          :      60
           
LIST OF EXPERIMENTS:

S.No
Name of the Experiment
No. of Periods
1
Identification of Ceramic Raw materials
02
2
Demonstration of Primary and secondary crushers for crushing of the material
02
3
Preparation of Clay models and Geometrical shapes
04
4
Determination of the Particle size analysis by Ro-Tap sieve shaker ( Ceramic powders and glass sand)
04
5
Determination of the moisture content of plastic and Non-plastic materials
04
6
Determination of Slaking of clays
04
7
Determination of Water of Plasticity of clays
06
8
Determination of the Linear shrinkage of specimen made of clays
05
9
Determination of the Volume shrinkage of clay specimen
05
10
Routine test for ceramic products like white ware/heavy clay ware /refractory/Glass/Cement etc
07
11
Determination of Density and Specific gravity of Ceramic  powders
07
12
Preparation of Cement brick and find the properties
06
13
Prepare different types of refractory bricks with given refractory mixture
04

Total
60

 


 

S.NO
OBJECTIVE
COMPETENCY
KEY COMPETENCY
1.
Identification of Raw materials.
-Identification of Raw materials used in Ceramic Industries based on Physical Properties.
-Know the Physical Properties like hardness, density, color, Streak, Luster, Fracture.

-Based on Physical  Properties Identify Raw materials.
2.
Determination of Crushers.
-Identification of different types of Primary & Secondary Crushers.
-Understanding the importance of Crushing.

-Know the Working Principle of different types of Crushers.

-Observe the Working of Crushers.
3.
Preparation of Clays &bodies.
-Making of different Geometrical Shapes & models using Clays &bodies.
-Measure the Volume of mold.
-Weigh the Raw materials.
-Mix with Water.
-Pressing in mold.
4.
Determination of Particle Size
-Identify different Sieves used in determination of Particle Size.
-Know the Relationship between Sieve No &Particle Size.
-Weighing of material.
-Transfer to a set of Sieves.
-Placed in Rotap Sieve Shaker for  5mm.
-Weigh the retain Components.
5.
Moisture Content
-Identify the Instruments used in measuring Moisture Content.
-Know the important of measuring Moisture Content.
-Understand the Working of Infrared Moisture balance.
6.
Determination of Slaking of Clays.
-To find the time of dissolving of Clays in water.
-The Students is able  to Understand the relationship between Slaking &Plasticity.
7.
Determination of Water  of Plasticity of Clay.
-To find amount of water required to make Plastic mass.
-The Student is able to Understand the importance of Plasticity.
8.
Determination of Linear Shrinkage of Specimen made of Clay.
-Select the Plastic or non Plastic Clay Which has to measure Linear Shrinkage.
-Make it in to Specimen by using suitable mold.
-then Dry and Fire at suitable temperature.
-Find out the Dry and Firing Shrinkages.
-Identify the Plastic & non Plastic Clays.
-Know the Drying &Firing.
-Know the Drying &Firing Shrinkage of the different Clays.
9.
Determination of the Volume Shrinkage of Clay Specimen.
-The Specimen was Prepare by using different Clays.
-Find out the Volume Drying Shrinkage &Volume Firing Shrinkage.
-Know the relationship between Liner Shrinkage to its Volume Shrinkage.
-Know the Volume Shrinkage of different Clays Which was used in the Ceramic Industry.
10.
Routine test for Ceramic Products like White ware/Heavy Clay ware/Refractory/Glass/Cement etc.
-Take the Specimens of the different ceramic products..
-Find out the density , porosity, water, absorption, SPGR etc.,
-Know the preparation of test specimen
-Know the different properties of the ceramic properties.
11.
Determination of density and SPGR of ceramic powders.
-To find out the density and SPGR of ceramic powders.

-Know the density and specific gravity of the different ceramic powders.
12.
Preparation of cement brick and find the properties.
-Prepare the standard brick by using OPC
-Find out the properties of the Cement Brick.
-Know the properties of the cement brick i.e., compressive Strength, Tensile Strength, porosity,water absorption etc.,
13
Prepare different types of refractory bricks with given refractory mixture
Prepare different shapes of brick by using given refractory mixture
Know the properties of the refrectory brick i.e., compressive Strength, Tensile Strength, porosity, water absorption etc.,

 




STATE BOARD OF TECHNICAL EDUCATION & TRAINING
ANDHRA PRADESH, HYDARABAD.
DIPLOMA IN CERAMIC TECHNOLAGY
3 ½ YEAR SANDWICH COURSE (UNDER MPEC SYSTEM)

SECOND SEMESTER

Subject
Name of  the Subject
Instruction Periods/Week
Total Periods/ Semester
Scheme of Examinations
Theory
Practical
Duration
(hrs)
Sessional Marks
End Exam Marks
Total Marks
Credits

THEORY SUBJECTS
CER-2107
English -II
03
-
45
3
20
80

100
3
CER-2108
Engineering Mathematics – II
05
-
75
3
20
80

100
5
CER-2109
Engineering Physics -II
04
-
60
3
20
80

100
4
CER-2110
Engineering Chemistry & Environmental Studies -II
04
-
60
3
20
80

100
4
CER-2204
Elements of Ceramic Technology -II
05
-
75
3
20
80

100
5

CER-2205
General Engineering
06
-
90
3
20
80

100
6

PRACTICAL SUBJECTS

CER-2111

2111-A Physics Laboratory-II
-
03
45

3

20
30

50

1.5

2111- B Chemistry Laboratory-II

-
20
30

50
CER-2112
Engineering Drawing-II
-
07
105
3
40
60

100
4.5
CER-2206
Computer Fundamental Practice- II
-
05
75
3
40
60

100
2.5

Total
27
15
630
-
280
720

900
35.5

ELEMENTS OF CERAMIC TECHNOLOGY-II

Subject Name                            : Elements of Ceramic TECHNOLOGY-II
SUBJECT CODE                             : CER-2204
Number of periods/ Week  : 05
PERIODS / SEMESTER                 : 75

TIME SHEDULE
S.NO
Major Topic
No. of Periods
Weightage of Marks
No. of Short Questions
No. of Essay Questions
1
Refractories                                                         
18
26
2
2
2
Glass                                                                          
20
26
2
2
3
Special Glasses
10
16
2
1
4
Enamels                                                                    
10
23
1
2
5
Cement                                                                       
10
16
2
1
6
Basic Concepts of
 Nano-Materials
07

03
1
--

Total
75
110
10
08

OBJECTIVES:  On completion of the course the student should be able to know the following:

1.0   REFRACTORIES:
1.1 Name the Natural and Synthetic Refractory materials.
1.2 Know the uses of refractory materials.
1.3 Define the term Refractory.
1.4 Understand the importance of Refractories in metal and Non-metal industries.
1.5 Know the Treatment of raw materials used in the Refractories.
1.6 Classify the Refractories.
1.7 List the varieties of refractory products like bricks, wool, cements, etc.
1.8  Know the Flow diagram for the manufacture of Fireclay, Dolomite, Magnesite, Chrome
       Magnesite and Silica Refractories.
1.9  Know the Drying of Refractories.
1.10 Name the Kilns for Firing of Refractories.
1.11 List the properties of Refractories.
1.12 List the tests conducted on Refractories.
1.13 Define the terms of each test

2.0   GLASS:
2.1 Know the difference between glass and ceramics.
2.2  Define the term glass.
2.3 Classify glass, by batch and oxide composition.
2.4 List the different types of glass.
2.5 Know the classification of glass making raw materials.
2.6 Know the function of each raw material in glass making
2.7  Know the schematic diagram of glass making oxides.
2.8 Know the term cullet and its importance.
2.9 Know the Glass batch preparation.
2.10 Know the Importance of weighing and mixing of batch materials.
2.11 Know flow sheet of Glass melting and understand the terminology used in melting of glass
2.12 Name the furnaces used for melting glass batch.
2.13 Name the fabrication techniques for glass products like pressing, blowing, drawing etc…
2.14 Know the Importance of annealing of glass.

3. SPECIAL GLASSES
3.1 Introduction to Special glasses
3.2 Know the composition and uses of fiber glass
3.3 Know the composition and uses of Pyrex glass
3.4 Know the composition and uses of flint glass
3.5 Know the composition and uses of crown glass
3.6 Know the composition and uses of amber glass
3.7 Know the composition and uses of optical glass
3.8 Know the composition and uses of safety glasses
3.9 Know the difference between glass and glass-ceramics
3.10 Know the composition and uses of glass ceramics
4.0 ENAMELS:
4.2  Define the term  Enamels.
4.3  Know the classification of enamel compositions
4.4  List the types of metals used in enamel industry.
4.5  Know the Preparation of metal surface for enameling.
4.6  Know the Flow diagram of frit making process.
4.7  List the frit making smelters and melters.
4.8  Know the Preparation of enamel slip.
4.8  Know the Flow diagram of Manufacture of Enamel ware
4.9  List the methods of enamel slip application techniques for enameling.
4.10 List the furnaces used in Firing of Enamel ware
4.11 Names the defects in enamel

5.0    CEMENT:
5.1   Define the term Cement.
5.2   Know the natural cement.
5.3   know the setting of cement.
5.4   Write the function of gypsum in the making of cement
5.6   Classify the raw materials used in the Cement making
5.7   Know the types of kilns used in cement manufacture
5.8   Draw the flow diagram of Manufacturing process of Wet and Dry methods
5.8   Know the term Clinker
5.9   Know the classification of the cements by composition
5.10 Know the Properties of different types of cements
5.11. Know the uses of cements
6. BASIC CONCEPTS OF NANO-MATERIALS

6.1 Know the Introduction of Nano-materials
6.2 Know the Applications of Nano-materials
6.3 List the preparation methods of Nano-materials

COURSE CONTENTS:

1.REFRACTORIES: Introduction to Refractories-Classification-Examples for Refractories- Treatment of Raw materials- Manufacturing process- Drying - Firing - Properties of Refractories -Test of Refractories.
2. GLASS: Introduction- Classification - Varieties of Glass Products- (Bottle glass- sheet glass- fiberglass etc.)  Raw materials used in Glass- Cullet- Glass Batch and Chemical composition- Glass batch mixing & Weighing- Glass melting - Shaping Techniques of – Annealing.
3. SPECIAL GLASSES: Introduction- composition, definition, uses of fiber glass, optical glass, pyrex glass, safety glass, crown glass, flint glass, glass ceramics etc…
4. ENAMELS: Introduction- Types of Enamels [Cast Iron, Sheet iron, and Steel]. Formation of metal shapes-Preparation of the metal surface for enameling- Enamel Compositions- Frit making & Frit making smelters- Milling & Mill additions-Methods of application of enamels- Firing.
5. CEMENT: Introduction-  Raw materials, Types of cements, Flow diagram of manufacturing process, Properties and uses.
6. BASIC CONCEPTS OF NANO-MATERIALS:  Introduction to Nanomaterials, Preparation and applications of Nanomaterials.

REFERENCE BOOKS:
1. R.Charan, Hand Book of Glass Technology,
2. Fay V. Tooley, Handbook of Glass Manufacture Volume I & II, Ogden Publishing Company, New York, 1960.
3. Samuel R Scholes, Modern Glass Practice, Industrial Publications, Inc., Chicago, 
    1952.
4. Andrews I. Andrews, Enamels –The preparation, Application and Properties of Vitreous Enamels, The Garrard Press, Publishers, Champaign, Illionois, 1949.
5. A Rashid Chesti, Refractories, Prentice Hall of Inida Pvt Ltd, New Delhi, 1986

6. D N Nandi, Hand Book on Refractories, Tata McGraw-Hill Publishing Co. New Delhi, 1991.

7. Dr. M. L. Misra, Refractories, Clear Type Press, Allahabad, 1975.
8. H N Banerjea, Technology of Portland cement and Blended Cement, Wheele

 

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GENERAL ENGINEERING


Subject Name                            :           GENERAL ENGINEERING
SUBJECT CODE                             :           CER- 2205
Number of periods/ Week  :           06
PERIODS / SEMESTER                 :           90

TIME SHEDULE
SL
No.
Major Topics
No. of Periods
Weightage of Marks
Short Type
Essay Type

ELECTRICAL ENGINEERING




1
Basic Principles Of Electricity                                                        
10
14
1
1
2
D.C.Machines                                                                          
12
11
1
1
3
A.C.Fundamentals &A.C.Circuits                                                                   
07
08
1
½
4
A.C.Machines                                                                       
13
14
1
1
5
Storage Batteries And Safety Procedures
05
08
1
½

MECHANICAL ENGINEERING:




6
Basic Workshop Tools
10
11
1
1
7
Mechanical Working Of Metals
07
08
1
½
8
Simple Stresses And Strains
10
14
1
1
9
Fundamentals Of Thermodynamics
06
08
1
½
10
Internal Combustion Engines
10
14
1
1

Total
90
110
10
8

OBJECTIVES:  On completion of the course the student should be able to know the following:


1.0  BASIC PRINCIPLES OF ELECTRICITY
1.1. Definition and units of electric potential, potential difference, voltage, electromotive force and electric current.
1.2. State the Ohm’s law
1.3. Compute resistance of a conductor given its length, area of cross section and resistivity.
1.4. State the Kirchoff’s laws.
1.5. Difference between series and parallel circuits.
1.6. Definition and units of electric power and electrical energy.
1.7. Definitions of magnetic flux, magnetic field strength, permeability and reluctance.
1.8. State Faraday’s laws of electromagnetic induction.
1.9. State Lenz’s law.
1.10. Definition of dynamically induced e.m.f. and statically induced e.m.f.
1.11. Definition of self inductance and Mutual inductance.
1.12. Definition of electric field, electric flux, electric field intensity and capacitance.

2.0  D.C. MACHINES
2.1. State constructional features of D.C.Machines.
2.2. Discuss working principle of D.C.Generator.
2.3. State formula for E.M.F equation of D.C.Generator (derivation is not required).
2.4. Solve the simple problems of E.M.F.
2.5. State types of D.C.Generator.
2.6. Draw the sketches of different types of D.C.Generator.
2.7. Working principle of D.C.Motor.
2.8. State types of D.C.Motors.
2.9. Draw the schematic diagram of the above D.C.Motors.
2.10 State the applications of D.C.Motors.
2.11.   State necessity of starter for D.C.Motor.

3.0.  A.C.FUNDAMENTALS & A.C.CIRCUITS
3.1.  Define Alternating current, cycle, amplitude, periodic time,
        frequency, instantaneous value and angular velocity.
3.2.  Define phase and phase difference.
3.3.  Define average value, RMS value, form factor and peak factor.
3.4.  Solve simple series circuits containing R,L and C.

4.0.  A.C.MACHINES
4.1.  Discuss working Principle of Alternator.
4.2.  e.m.f. Equation of an alternator (derivation not required) and solve simple problems.
4.3.  Describe the working principle of transformer.
4.4.  Write the e.m.f. Equation pf transformer and solve simple problems (derivation not required).
4.5.  Describe the definition of Turn ratio.
4.6.  Describe the working principle of 3ø induction motor.
4.7.  State different types of 3ø induction motors and their applications.
4.8.  Describe working principle of 1ø induction motor.
4.9.  State the different types of 1ø induction motors and their applications.
4.10. State the principle of operation of Synchronous motor.
4.11. State the applications of synchronous motor.

5.0.  STORAGE BATTERIES AND SAFETEY PROCEDURES:
5.1.  State different types of cells.
5.2.  State the active materials of Lead acid cell.
5.3.  State the chemical reaction during charging and discharging of a Lead acid cell.
5.4.  Write difference between lead acid cell and Nickel Iron cell.
5.5.  Write the usage of storage batteries.
5.6.  State the effect of electrical shock and burns.
5.7.  State the precautions to be taken against electrical shock.
5.8.  Discuss the procedures to be adopted in case of electric shock.

6.0.  BASIC WORKSHOP TOOLS

6.1    State the Classification of various workshop tools.
6.2    Sketch the various marking and measuring tools in workshop as such steel rule, calipers, divider, Vernier calipers, sine bar, filler gauge. Wire gauge, plate gauge, Tri square, Marking knife, scriber, pick punch.
6.3    Describe with neat sketches the various cutting tools used in workshop such as saw, snips, chisels, drills, wheels brace, jackplane, File etc.
6.4    Describe with neat sketches the various striking tools used in work shop such as Warrington hammer, claw hammer, sledge hammer, mallet etc.
6.5    Describe with neat sketches the various holding tools used in work shop such as bench vice, pipe vice, hand vice etc.
6.6    Describe with neat sketches the various miscellaneous tools used in workshop such as pincer, screwdriver, spanners, pliers.
6.7    Describe with neat sketches the various machine tools like lathe, drilling machine used in workshop.
7.0      MECHANICAL WORKING OF METALS
            7.1    Define hot working.
7.2    List the advantages and disadvantages of hot working.
7.3    Illustrate the working principle of various hot working processes like rolling, 
         extrusion, forging, piercing, reeling, spinning, drawing etc.
7.4    Define Cold working.
7.5    List the advantages and disadvantages of cold working.
7.6    Illustrate the working principle of various cold working processes like rolling, drawing, extrusion, embossing, joining, bending etc.
7.7    Comparison of hot working with cold working.

8.0      SIMPLE STRESSES AND STRAINS
8.1      Define the stress.
8.2      Define the Strain.
8.3      State the Poisson’s ratio.
8.4      State the different types of stresses and strains.
8.5      Discuss about elastic limit.
8.6      State Hook’s law.
8.7      Define Modulus of elasticity.
8.8      State and explain Thermal stresses.
8.9      Compute stress and strain relating bodies of uniform section, changes in lateral and volumetric dimensions of bodies of uniform section under the action of normal forces and thermal stress as in bodies of uniform section.

9.0      FUNDAMENTALS OF THERMODYNAMICS
9.1.    Define the term of Heat.
9.2.    Discuss about Temperature.
9.3.    Discuss about Specific heat.
9.4.    State the laws of thermodynamics.
9.5.    State and explain law of perfect gases.
9.6.    Define internal energy.
9.7.    State law of internal energy.
9.8.    State law of conservation of energy.
10.0.    INTERNAL COMBUSTION ENGINES
           10.1    Define Heat engine.
           10.2    Classify of heat engines with examples.
           10.3    Discuss internal combustion engine terminology.
10.4    Explain with a line diagram of the working of a Four-stroke petrol engine with a neat line diagram.
10.5    Explain with a line diagram of the working of a Four-stroke diesel engine.
10.6    Explain with line diagram the working of Two-stroke petrol engine.
10.7    Explain with line diagram the working of Two-stroke diesel engine.
10.8    Compare two-stroke engine with four-stroke engine.
10.9    Compare diesel engine with petrol engine.
10.10  Draw the Line diagram of fuel supply system in petrol engine.
10.11  Draw the Line diagram of fuel injection system for C.I engines.
10.12  Understand the necessity of cooling for I.C engine.
10.13  Describe the methods of cooling like air-cooling system and water-cooling system.

COURSE CONTENTS:

1. BASIC PRINCIPELS OF ELECTRICITY: Define and state units of electric potential, potential difference, voltage, electromotive force and electric current. Ohm’s law. Compute resistance of a conductor given its length, area of crosssection and resistivity. Kirchoff’s laws. Series and parallel circuits. Definitions ofelectric power and electrical energy, magnetic flux, magnetic field strength,permeability and reluctance. Faraday’s laws of electromagnetic induction.Lenz’s law. Dynamically induced e.m.f. and statically induced e.m.f. Selfinductance and Mutual inductance. Define electric field, electric flux, electric field intensity and capacitance.

2. D.C. MACHINES: D.C.Machines. D.C.Generator.Formula for E.M.F equation of D.C.Generator and solve the simple equations. Types of D.C.Generator. Working principle of  D.C.Motor, Types of D.C.Motors, uses all  D.C.Motors. Starter of a D.C.Motor.

3. A.C.FUNDAMENTALS & A.C.CIRCUITS: Define Alternating current, cycle, amplitude, periodic time, frequency, instantaneous value and angular velocity. Phase and phase difference, Define average value, RMS value, form factor and peak factor, Solve simple series circuits containing R,L and C.

4.  A.C.MACHINES: Working Principle of Alternator. E.M.F. Equation of an alternator and Solve simple problems.Working principle of transformer. E.M.F. Equation of transformer and solve simple problems. Define Turn ratio, working principle of 3ø induction motor and single phase induction motor and its types and uses. Synchronous motor and its applications.

5. STORAGE BATTERIES AND SAFETEY PROCEDURES: Types of Cells, active materials of Lead acid cell, Nickel Iron cell, uses of storage batteries. Electrical shock and burns and its effects. Precautions for electrical shock.

6. BASIC WORK SHOP TOOLS: Classification, hand tools, marking, and measuring tools, striking tools, holding tools, miscellaneous tools and uses.

7. MECHANICAL WORKING OF METALS: Hot working process, cold working process, advantages and disadvantages of both and comparison.

8. SIMPLE STRESSES AND STRAINS: Stress, Strain, Various types of stresses and strains. Hook’s law, Module of elasticity, lateral strain, Poisson’s ratio, calculation of stress, strain and dimensional changes in bodies, thermal stresses.

9. FUNDAMENTALS OF THERMODYNAMICS: Heat, temperature, specific heat, loss of thermodynamics, loss of perfect gases, internal energy, law of conservation of energy.

10. INTERNAL COMBUSTION ENGINES: Definition,  examples, classification, I.C. engine parts, engine terminology, four stoke (petrol and diesel) engines, Two stroke (petrol and diesel ) engines, Four stroke vs. two stroke, petrol va. Diesel engines, fuel supply system in a petrol engines, fuel injections system for diesel engines, cooling system of I.C. engine, necessity of cooling and methods of cooling.
REFERENCE BOOKS:
1.      BL Theroja and AKTheroja, Electrical  Technology Volume I and II
2.      Theraja, B.L., Fundamentals of Electrical Engineering”, NirajPrakashma 1966.
3.      RS Khurmi, Strength of Materials,
4.      RS Khurmi, A text book on Mechanical technology,
5.      BL Theroja and AKTheroja, Electrical  Technology Volume I and II
6.      Hajra Choudhery, Elements of Workshop Technology.
7.      B.S. Raghuvamsi, Workshop Technology
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