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You are on page 1of 44

It is an interactive PDF file just click on the content and you will be directed to the required page

General Instructions

Production Engineering

Some functions

1. Exp

Shear angle

2. ln

3. log

4. logyx

5. ex

6.

10x

7.

xy

8.

Shear strain

Velocity relations

Merchant Circle

Force Relations

Turning

Specific Energy

Linear Interpolation

Tool life equation

9.

Linear regression

10.

Economics

11.1/x

Metrology

Rolling

Forging

tanh-1

15. Linear Interpolation

16. Linear regression

Extrusion

Wire Drawing

Sheet Metal Operation

Casting

Welding

Machine Tools

ECM Calculation

Strength of Materials

Elongation

Thermal Stress

Principal stresses

Deflection of Beams

Bending stresses

Torsion

Spring

Theories of column

Theories of Failure

Theory of Machines

Frequency

Transmissibility ratio

Thermodynamics

SFEE

Entropy Change

Available Energy

Heat and Mass Transfer

Conduction

Unsteady Conduction

Heat Exchanger

Radiation

Industrial Engineering

Forecasting

Regression Analysis

Optimum run size

2|Page

General Instructions

calculator. Hence all students are requested to practice the following procedures.

calculate part by part.

B Bracket

O Order (Power and roots)

D Division

M Multiplication

A Addition

S Subtraction

For answer must click on =

[= means you have to click on this = button]

[ C means you have to click on this C button]

For writing sin30 first write 30 and then click on sin (same procedure should be

follow for all trigonometric calculations)

[ sin means you have to click on this sin button]

Here mod button is simply a showpiece never press mod button. It is indicating

calculator is in deg mode or in rad mode. For changing degree mode to radian

mode you have to press radio button.

Some functions

1. Exp

It is actually power of 10

102

Made Easy

1 Exp 2 =

100

By: S K Mondal

3|Page

200 GPa

200 Exp 9 =

2. ln

ln2

2 ln =

0.6931472

2ln2

2 * 2 ln =

1.386294

3ln5

3 * 5 ln =

4.828314

Made Easy

By: S K Mondal

4|Page

3. log

log100

100 log =

5 log50

5 * 50 log =

8.494850

4. logyx

log10100

100

logyx

10 =

Note: you have to first type value of x then logyx button then value of y. Logically

value of x should be given first then value of y.

Made Easy

By: S K Mondal

5|Page

log550

50 logyx 5

7log550

7 * ( 50 logyx 5 ) =

2.430677

17.01474

350 logx Base y and give wrong answer. But see in case of 5 log50 we simply use

5 * 50 log = 8.494850 and no need of ( ).

5. eX

e2

2 eX

7.389056

5 e2

5 * 2 eX

36.94528

4 e(5 x 3.4 1)

4 * ( 5 x 3.4 1 ) eX =

3.554444e+7

6. 10X

102

2 10X

100

Made Easy

By: S K Mondal

6|Page

5 x 102

5 * 2 10X

105/3

(5/3) 10X

10

1.41

1.4

(1.41)

)

1.4

10(

500

46.41592

1.930698

10

1.41

1.4

0.4

10(1.4)

(0.4/1.4)10X =

1.930698

7. Xy

23

2 xy

3 =

Note: you have to first type value of x then xy button then value of y. Logically

value of x should be given first then value of y.

Made Easy

By: S K Mondal

7|Page

2

1

1.4

1.41

(5/3) xy 1.4/(1.4 1) =

8.

5.111263

32

32

5 =

Note: you have to first type value of x then button then value of y. Logically

value of x should be given first then value of y.

32 = 321/5 = 32 xy (1/5) =

But in this case (1/5) is must you cant use 32 xy 1/5 wrong

9.

5

Made Easy

5 +/- =

By: S K Mondal

8|Page

10.

5

2.236068

32 + 42 =

32 + 42

= ( 3 x2 + 4 x2 )

But

=

=

1

2

1

2

1 2

+ 2 3

97.74 22.96

+ 3 1

+ 22.96 20

+ 20 97.74

Made Easy

By: S K Mondal

9|Page

x2 =

97.74 22.96

5592.048

22.96 20

x2 =

8.7616

20 97.74

x2 =

6043.508

Now press button 107.9089

[ it is =

97.74 22.96

+ 22.96 20

+ 20 97.74

107.9089 / 2

Therefore, =

76.30309

97.74 22.96

+ 22.96 20

+ 20 97.74

= 76.30309

11. 1/x

This is generally used at middle of calculation.

0.4512

1 0.4512

We first calculate 1 0.45sin12 then use 1/x button.

1 0.45 * 12 sin

Made Easy

0.9064397

By: S K Mondal

10 | P a g e

12. sin

cos

1.103217

0.4855991

tan

Always value should be given first then the function.

Made Easy

By: S K Mondal

11 | P a g e

sin30

30 sin

0.5

cos45

45 cos

tan30

30 tan =

Made Easy

0.707

0.577

By: S K Mondal

12 | P a g e

sin230

(30 sin ) x2

0.25

cos245

(45 cos ) x2 =

0.5

tan230

(30 tan ) x2 =

0.3333333

(30 10.5 ) sin =

0.3338

( 20.15 + 33 - 10) cos =

0.729565

(17.3 10 ) tan =

0.128103

2.0

= 2 20 = 2.0/(20 sin ) x2

13. sin-1

cos-1

17.09726

tan-1

If needed in radians calculate by

multiplying /180. We may use in rad mode but i will not recommend it because

students forget to change the mode to degree and further calculations may go

wrong.

sin-10.5

Made Easy

0.5 sin-1

30

degree

By: S K Mondal

13 | P a g e

cos-10.5

0.5 cos-1

60

tan-10.5

0.5 tan-1

26.565 degree

degree

3!

3 n!

5!

5 n!

120

25!

25 n!

Made Easy

By: S K Mondal

14 | P a g e

You have to first calculate upto last form

1

1

=

2 1 2 1

1.8 0.8

10

=

2.0 0.8 60 10

10 = 60 10

1.8 0.8

2.0 0.8

= 10 + 60 10

1.8 0.8

2.0 0.8

Made Easy

51.66667

By: S K Mondal

15 | P a g e

Let us assume the equation which best fit the given data

y = A + Bx

First take summation of both sides

= +

. . ()

xy = Ax + Bx2

Again take summation of both sides

= + 2

. . ()

Example:

Data

1

2

3

x

1

2

3

= 6

For 1 + 2 + 3 = 6

y

1

2

3

= 6

xy

1 x1

2x2

3x3

= 14

x2

12

22

32

2 = 14

For 1 + 2 + 3 = 6

For 1 * 1 + 2 * 2 + 3 * 3 = 14

For 2 Use M+ button

12

1 x2 M+

22

2 x2 M+

32

3 x2 M+

Now = +

or

6 = 3 + 6

Made Easy

. . ()

. . ()

By: S K Mondal

16 | P a g e

and = + 2

or

14 = 6A + 14 B

. . ()

. . ()

y = 0 + 1. x is the solution.

Made Easy

By: S K Mondal

17 | P a g e

Production Engineering

Theory of Metal Cutting

Shear angle ()

= 1 =

=

0.45 12

10.45 12

0.45 * 12 cos / ( 1 0.45 * 12 sin ) =

0.4855991

Then find

Just press button tan-1

25.901

Shear strain ()

= + tan

( )

= 17.3 + tan

(17.3 10)

1

= 17.3 + tan

(17.3 10)

It is a long calculation; we have to use M+

1

17.3

= 1 / 17.3 tan

tan

(17.3 10) = (17.3 - 10) tan

3.210630

=

0.1281029 M+

Then find

Just press button MR

3.338732

( ) = 17.3 + tan

(17.3 10) = 3.34

Made Easy

By: S K Mondal

18 | P a g e

Velocity relations

10

=

2.5 22.94 10

= 2.5

10

22.94 10

2.526173

Merchant Circle

(i)

= = 285

30.51

20.15

(ii)

1265.824

= +

=

1265.8

=

+

20.15 + 33 10

[We have to use extra bracket for denominator]

1735.005

Force Relations

=

= 900 30 600 30

900 * 30 cos - 600 * 30 sin

Made Easy

479.4229

By: S K Mondal

19 | P a g e

Turning

(i)

= = 0.32 75

0.32 * 75 sin

(ii)

=

=

0.3091

800

75

800 / ( 75 sin )

828.2209

Specific Energy

= 1000 =

800

1000 0.22

You have to first calculate upto last form

1

1

=

2 1 2 1

1.8 0.8

10

=

2.0 0.8 60 10

10 = 60 10

1.8 0.8

2.0 0.8

= 10 + 60 10

1.8 0.8

2.0 0.8

Made Easy

51.66667

By: S K Mondal

20 | P a g e

(i)

1 1 = 2 2

or 100 10 = 75 30

or

100

or

75

30

10

= 3

or

or =

= 3

3

4

3

(4/3) ln / ( 3 ln )

(ii)

0.2618593

Find C

C = 100 x 1200.3

100 * 120 xy 0.3 =

(iii)

3 = 1

= 30

420.4887

60 0.204

30

30 * ( 60 / 30 ) xy 0.204 =

(iv)

90 0.45

>

60 0.3

90 0.45

or

or

90 0.3

Made Easy

34.55664

=

=

60 0.3

60 0.45

By: S K Mondal

21 | P a g e

or

0.45

0.3

or

0.15

60 0.45

900.3

60 0.45

900.3

or = 1.636422

= 60 xy 0.45

/ 90 xy 0.30 = 1.636422

1

0.15

26.66667

Let us assume the equation which best fit the given data

y = A + Bx

First take summation of both sides

= +

. . ()

xy = Ax + Bx2

Again take summation of both sides

= + 2

. . ()

Example:

Data

1

2

3

X

1

2

3

= 6

For 1 + 2 + 3 = 6

y

1

2

3

= 6

xy

1 x1

2x2

3x3

= 14

x2

12

22

32

2 = 14

For 1 + 2 + 3 = 6

For 1 * 1 + 2 * 2 + 3 * 3 = 14

For 2 Use M+ button

Made Easy

By: S K Mondal

22 | P a g e

12

1 x2 M+

22

2 x2 M+

32

3 x2 M+

Now = +

or

6 = 3 + 6

. . ()

. . ()

and = + 2

or

14 = 6A + 14 B

. . ()

. . ()

y = 0 + 1. x is the solution.

6.5

0.5

1 0.2

0.2

= +

= 3 +

64 min

Now =

or 64

0.2

= 60

60

or = 64 0.2

60 / 64 xy 0.2 =

Made Easy

26.11 m/min

By: S K Mondal

23 | P a g e

Metrology

3

= 0.45 + 0.001

3

0.45 * 97.98

+ 0.001 * 97.98

2.172535

Rolling

cos = 1

5

= 1

600

= 1 - 5 / 600

cos-1

7.40198o

If you want in radian after calculating 7.40198 just press * /180 and you will

get = 0.129189

Forging

(i)

12

4

1 =

2 = 1

22

4

1

50

= 100

= 100 2

2

25

100 * ( 50 / 25)

or 100 * 2

(ii)

= 48

141.4214

141.4214

6

20.25

1

20.25

48 (6 / 2 / 0.25 ) * (1 / 2 / 0.25 ) ln

(iii)

= 2

39.68223

Made Easy

By: S K Mondal

24 | P a g e

= 2 +

= 2 +

2

2

= 2 + 2

4.04

6

39.682

510418.2

= 510418.2

= 2

= 4

= 4

=

=

4

2

2 4.04 150 6

0.25

20.25

4839.68

6

This is very large calculation; this weak calculator cant handle at once, we have

to calculate part by part

First calculate (2 * 4.04 * 150 * 6 / 0.25) =

29088

Made Easy

1.000372

By: S K Mondal

25 | P a g e

29098.82

= 29098.82

= + = 510418.2 + 29098.82 = 539517 = 539.52

Extrusion

= 2

82

5

= 2 400

4

4

It is a long calculation, after some part we press

multiplication is done .

2 * 400 * ( * 8 x2 / 4) =

Now 40212.38 * (5 / 4) ln

it gives 40212.38

=

8973.135 N

Wire Drawing

(i)

1+

1 + 1.7145

5

= 400

1

1.7145

6.25

21.7145

It is a long calculation,

First calculate, 400

1+1.7145

1.7145

633.3040

Then calculate,

1

5

6.25

21.7145

= (1 (5 / 6.25) xy (2 * 1.7145)) =

0.5347402

338.65 MPa

[At that time in your calculator 0.5347402 is present just multiply it with

previous value 633.3040]

Made Easy

By: S K Mondal

26 | P a g e

(ii)

1+

400 = 400

Let

or

1 + 1.7145

1

1.7145

6.25

21.7145

6.25

21.7145

6.25

21.7145

50

400 = 400

Calculate, 400

or

1+1.7145

1.7145

1+1.7145

1 + 50

1.7145

633.3

400 = 633.3 1 + 50

633.3400

or =

633.350

0.4 =

or = 6.25 0.4

21.7145

6.25

1

21.7145

4.784413 mm

(i)

= 0.0032

= 0.0032 1.5 294

0.0032 * 1.5 * 294

(ii)

0.08230286 mm

=

= 2 + = 2 100 + 50 5 300

2 * (100+50) * 5 * 300

(iii)

450000 N = 450 KN

= 2 + 4

=

252 + 4 25 15

( 25 x2 + 4 * 25 * 15)

Made Easy

=

46.09772 mm

By: S K Mondal

27 | P a g e

(iv)

1 2

1.5

0.05 0.09

1.304038 mm

Casting

(i)

=

=

2

4

0.1202

0.180 11300 1600 9.81

4

(ii)

193.7161 N

B * (V / A) x2

Welding

(i)

+ = 1

45

500

+

=1

. . ()

55

400

+

=1

. . ()

55 5 45 4

= 54 = 1

or OCV = 95 V

Now from equation (i)

Made Easy

By: S K Mondal

28 | P a g e

45 500

+

=1

95

500

45

or = 1 95

or =

500

45

95

500 / ( 1 45 / 95)

(ii)

950 V

30000 x2 * 100 * 6 +/- 10x * 0.005

450 J

Machine Tools

(i)

Turning time ( T ) =

++

(L+A+O) / (f *N)

(ii)

Drilling time ( T ) =

+++

L = 50 mm

=

15

=

= 15/ (2 59 tan ) = 4.5

2

2 59

A = 2 mm

O = 2 mm

f = 0.2 mm/rev

N = 500 rpm

=

50 + 4.5 + 2 + 2

0.2 500

Made Easy

0.585 min

By: S K Mondal

29 | P a g e

ECM Calculation

(i)

1 1 2 3 4

= + + +

1 2 3 4

or

0.7

8.9

0.2

7.19

0.05

7.86

0.05

4.51

First calculate

0.7 / 8.9 +0.2 / 7.19 +0.05 / 7.86 +0.05 / 4.51 =

0.1239159

= 8.069989 /

(ii)

1 1 2 3 4

=

+ + +

1 2 3 4

or

or

=

=

1 1

1

0.72

58.71

2 2

0.22

51.99

3 3

3

4 4

0.052

55.85

0.053

47.9

First calculate

0.7 * 2 / 58.71+0.2 * 2 / 51.99+0.05 * 2 / 55.85+0.05 * 3 / 47.9 =

0.03646185

= 27.42593

Alternate Method 1:

First calculate

0.7 * 2 / 58.71 =

0.02384602

0.03153981

Then 0.03333032 + 0.05 * 3 / 47.9 =

0.03646185

Made Easy

By: S K Mondal

30 | P a g e

= 27.42593

Alternate Method 2: Use M+ button

0.7 * 2 / 58.71 =

0.05 * 2 / 55.85 = 0.001790511 press M+ button the press C button

0.05 * 3 / 47.9 =

= 27.42593

Made Easy

By: S K Mondal

31 | P a g e

Strength of Materials

(Only for the type of equations which are not yet covered)

Elongation

(i)

or =

or =

1010 3 1000

5 2

20010 3

4

1004

52 2

[After cancelling common terms from numerator and denominator and one extra

bracket in the denominator has to be put]

100 * 4 / ( * 5 x2 * 2)

2.546480 mm

Thermal Stress

(ii)

0.512.510 6 20

1+

500.5

0.01 2

200 10 6

4

First calculate

500.5

0.01 2

4

20010 6

500.54

0.012 20010 6

0.001591550

Then add 1

0.001591550 + 1

1.001592

Made Easy

By: S K Mondal

32 | P a g e

0.9984105

Then multiply with 0.5 12.5 106 20

0.9984105 * 0.5 * 12.5 * 6 +/- 10x * 20 =

0.0001248013

(iii)

+

2

80 20

2

+ 402

[One bracket for denominator one bracket for square and one for square root]

(((80-20) / 2 ) x2 + 40 x2 )

For

1,2 =

+

2

First calculate

2

2

50 MPa

2

+

+

2

2

2

+

Deflection of Beams

(iv)

4

8

1010 3 54

8781250

10 * 3 10x * 5 xy 4 / (8 * 781250 ) =

Made Easy

1 mm

By: S K Mondal

33 | P a g e

Bending stresses

(v)

9.5710

=

=

0.1

0.10.2

12

Pa

9.57 103 12

0.23

Torsion

(vi)

409.256

32

10.74 4

or

4 =

8010 9

1180

32409.256180

2

10.74 8010 9

Then calculate 2 1 0.74 80 109

x2 * (1 0.7 xy 4) * 80 * 9 10x

Now 4

2357315

5.99993010 11

5.999930e+11

= 0.000003928904

Spring

(vii)

8 3

Made Easy

By: S K Mondal

34 | P a g e

820010 3 10 6 10

8010 9 84 10 12

8*200*310x 6 +/- 10x 10 /(80* 9 10x 8 xy 4 * 12 +/- 10x ) =

0.04882813 m

= 48.83 mm

Theories of column

(viii)

42

3

10 10 =

4

64

2 21010 9

44 2

or 10 10 4 42 64 = 2 210 10

or 4 =

1010 3 442 64

3 21010 9

10 * 3 10x * 4 * 4 x2 * 64

= 4.096000e+7

x3 * 210 * 9 10x

4 =

= 6.511319e+12

4.096000e + 7

= 0.000006290584

6.511319 + 12

Theories of Failure

(ix)

=

=

1

2

1

2

1 2

+ 2 3

97.74 22.96

+ 3 1

+ 22.96 20

+ 20 97.74

97.74 22.96

Made Easy

x2 =

5592.048

By: S K Mondal

35 | P a g e

22.96 20

x2 =

8.7616

20 97.74

x2 =

6043.508

Now press button 107.9089

[ it is =

97.74 22.96

+ 22.96 20

+ 20 97.74

107.9089 / 2

Therefore, =

=

1

2

76.30309

97.74 22.96

+ 22.96 20

+ 20 97.74

= 76.30309

Made Easy

By: S K Mondal

36 | P a g e

Theory of Machines

(Only for the type of equations which are not yet covered)

Frequency

(i)

4010 3

100

(40 * 10 x3 / 100 ) / 2 /

3.183099

Transmissibility ratio

(ii)

1+ 2 2

1 2 2 + 2 2

1 + 2 0.15 18.85

1 18.852

First calculate 2

(2 * 0.15

PressM+

Next find 1 2

+ 2 0.15 18.85

= 2 0.15 18.85

* 18.85 ) x2

= 1 18.852

(1 18.85 x2 ) x2

125544.4

Press MR + 1 =

then press

5.742737

Press MR + 125544.4 =

then press

354.3676

Press 1/x and * 5.742737 =

0.01620559

TR = 0.01620559 (Answer)

Made Easy

By: S K Mondal

37 | P a g e

Thermodynamics

(Only for the type of equations which are not yet covered)

SFEE

(i)

1 +

12

2000

1000

= 1 +

12

2000

1000

1602 9.81 10

1002 9.81 6

3200 +

+

+ 0 = 2600 +

+

+

2000

1000

2000

1000

M+

3200

M+

=

M+

Press M+

M-

M-

M-

2600

Press M-

1602 9.81 10

1002 9.81 6

= 3200 +

+

2600

2000

1000

2000

1000

Entropy Change

(ii)

= 1.005

M+

Made Easy

300

50

0.287

350

150

M-

By: S K Mondal

38 | P a g e

First calculate

1.005

300

350

Then calculate 0.287

50

150

-0.3153016 Press M-

= 0.16 /

Available Energy

(iii)

2 1

2

1

First calculate

1250

450

1250

450

490.4397

490.4397 * 2000 * 0.5 =

Made Easy

490439.7 KJ = 490.44 MJ

By: S K Mondal

39 | P a g e

(Only for the type of equations which are not covered yet)

Conduction

(i)

2

1

3

2

+

2 1 1200 600

0.025

0.055

0.01 +

0.025

19

0.2

0.025

0.01

19

0.055

0.025

0.2

Calculate

(0.025 / 0.01) ln / 19 = 0.04822583 Press M+ then press C button

Then

(0.055 / 0.025) ln / 0.2 = 3.942287 Press M+

Then press MR it is denominator

3.9905128299999996

Multiply with Numerator 2 1 1200 600

0.2505944 * 2 * * 600 =

Made Easy

944.7186

W/m

2 1 1200 600

= 944.72 /

0.025

0.055

0.01 +

0.025

19

0.2

By: S K Mondal

40 | P a g e

Unsteady Conduction

(ii)

= =

298 300

3

= 4252.3533 10

30 300

or

298300

or

30300

30300

298300

30300

or

298 300

4252.3533 10 3

((30-300) / (298-300)) ln =

Note: Several times use of

/ 425 =

=

/ 2.3533 =

/ 3 +/- 10x =

4.904526 S

Heat Exchanger

(iii)

9040

90

40

(90 / 40) ln = then press 1/x then multiply with numerator * (90 40) = 61.65760

Radiation

(iii)

Interchange factor

12 =

1

1 1 1

+

1

1 2 2

First calculate

1

1 210 3 1

+

1

0.6

100

0.3

210 3

100

0.3

Made Easy

0.00004666666

By: S K Mondal

41 | P a g e

0.00004666666 + 1 / 0.6 ) =

1.666714

0.5999830

f12 =0.5999830 0.6

Now

= 12 1 14 24

First calculate 0.6 5.67 108 2 103

0.6 * 5.67 * 8 +/- 10x * 2 * 3 +/- 10x =

6.804000e-11

6.804000e-11 * (800 xy 4 - 300 xy 4) = 27.31806 W

= 0.6 5.67 108 2 103 8004 3004 = 27.32

Made Easy

By: S K Mondal

42 | P a g e

Industrial Engineering

(Only for the type of equations which are not yet covered)

Forecasting

(i)

= + 1 1 + 1 2 2 + 1 3 3

= 0.4 95 + 0.4 0.6 82 + 0.4 0.62 68 + 0.4 0.63 70

M+

0.4 * 95

M+

=

0.4 * 0.6 * 82

38

M+

M+

0.4 * 0.6 x2 * 68

0.4 * 0.6 x3 * 70

6.048 Press M+

= 0.4 95 + 0.4 0.6 82 + 0.4 0.62 68 + 0.4 0.63 70 =73.52

Regression Analysis

(ii)

Let us assume the equation which best fit the given data

y = A + Bx

First take summation of both sides

= +

. . ()

xy = Ax + Bx2

Again take summation of both sides

= + 2

. . ()

Example:

Made Easy

By: S K Mondal

43 | P a g e

Data

1

2

3

x

1

2

3

= 6

For 1 + 2 + 3 = 6

Y

1

2

3

= 6

Xy

1 x1

2x2

3x3

= 14

x2

12

22

32

2

= 14

For 1 + 2 + 3 = 6

For 1 * 1 + 2 * 2 + 3 * 3 = 14

For 2 Use M+ button

12

1 x2 M+

22

2 x2 M+

32

3 x2 M+

Now = +

or

6 = 3 + 6

. . ()

. . ()

and = + 2

or

14 = 6A + 14 B

. . ()

. . ()

y = 0 + 1. x is the solution.

Made Easy

By: S K Mondal

44 | P a g e

(iii)

2 30000 3500

2.5 + 10

2.5

10

First calculate

230000 3500

2.5

2.5+10

10

1.050000e+8

1.050000e+8 =

10246.95

END

If you got the above points, of the way of calculation then you should be happy enough

because we finally succeeded in its usage.

Made Easy

By: S K Mondal

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