Mechanical Enginnering Paper II

Mains Exam
Solution
MECHANICAL ENGINEERING - Paper II
SECTION–A
Q.1: (a) (i) A 10 m boom AB weighs 1 kN. The distance of centre of gravity is 5 m from A. For
the position shown in the figure given below, determine the tension T in the cable and
reaction at A: [6 Marks]
15°
G 3 kN
C 30° 1 kN
A
1
(ii) A rope making 1 turns around a stationary horizontal drum is used to support a
4
weight as shown in the figure given below. If the coefficient of friction is 0.3, what
range of weight can be supported by exerting an 800 N force at the end of the rope?
800 N
W
[6 Marks]
Sol. (i) Let the tension in the cable is ‘T’
To find out T,
+ MA  0
T cos 15° B
15°
T 15° T sin 15°
3kN
5m
5m
1 kN
A 30°
HA
VA
3 × 10 cos30° + 1 × 5 cos30° + T sin15° × 10 cos30° – T cos15° × 10 sin30° = 0

 T = 11.711 kN
Now, in order to determine the reactions at ‘A’, consider the equilibrium of forces as shown above
  Fv  0
 VA – 1 – 3 – T sin 15° = 0
 VA – 1 – 3 – 11.711 sin 15° = 0
 VA = 7.031 kN
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Mains Exam
Solution

Also  FH  0
 HA – T cos 15° = 0
 HA – 11.711 cos 15° = 0
 HA = 11.312 kN
1
(ii) Angle of wrap,  = 1  360  450
4
coefficient of friction,  = 0.3
Fpull = 800 N
Fweight = W N
Fpull
 = e
Fweight
800 
= e  0.3450180
W
 W = 75.82 N
So, the range of weight supported by 800 N force is 0 to 75.82 N.
Comment : If weight w exceeds 75.82 N then force 800 N will not be sufficient to support the weight.
Q.1: (b) A steel tube of 100 mm internal diameter and 10 mm wall thickness in a plant is lined
internally with well-fitted copper sleeve of 2 mm wall thickness. If the composite tube is
initially unstressed, calculate the hoop stress set up assumed to be uniform throughout the
wall thickness, in a unit length of each part of the tube due to an increase in temperature
of 100°C.
For steel, E = 208 GPa,  = 11 × 10–6/°C
For copper, E = 104 GPa,  = 18 × 10–6°C [12 Marks]
Sol. (b)
t1
t2
R = 50 mm
t1 = 10 mm
t2 = 2 mm
Since thin cylinders, h will be assumed to be constant throughout
Since copper   steel .
Mains Exam
Solution
 (R)th,copper  ( R)th,steel , this will induce stresses in tube and sleeve.
(h )copper will be compressible and (h )steel will be tensile.

Assuming contact pressure P0,
 P0D   P0D 
(h )steel =  2t  ;  h copper =  2t 
 1  2
  h  
Radial displacement for steel due to pressure and temperature =  E  s T  R
 s 
 h 
Radial displacement for copper =  E  c T  R
 C 
(Radial displacement)copper =(Radial displacement)steel
 h    
   s T  R =   h  c T  R
 Es   Ec 
P0D  1   1   P0D 
     
2t1  Es   Ec   2 t 2  = (c   s )T
P0  120  1  P0  120  1 
   = 7 × 10–6 × 100
2  10  208  1000  2  2  104  1000 

P0 = 2.206 MPa
P0D 2.206  120
 h steel =   13.236 MPa
2t1 2  10
P0D 2.206  120

 h copper = 2t  2 2
 66.18 MPa
2
Q.1: (c) (i) What is kinematic pair? How are kinematic pairs classified? Explain. [6 Marks]
(ii) A four-bar mechanism has the following dimensions:
DA = 200 mm, CB = AB = 300 mm, DC = 500 mm
The link DC is fixed and the angle ADC is 60°. The driving link DA rotates uniformly
at a speed of 100 r.p.m. clockwise and constant driving torque has the magnitude of
50 N-m. Determine the velocity of point B and angular velocity of the driven link CB.
If the efficiency is 70%, calculate also the resisting torque: [6 Marks]
B
60°
D
C
Sol. (i) Kinematic Pair: When two links of a machine is in contact, this contact is called a pair. If the
motion between the links forming the pair is in a specific directions irrespective of the directions
of force, the pair is called kinematic pair and the motion of link is called as completely or
successfully constrained.
Mains Exam
Solution
Classification of Kinematic Pair

(1) Kinematic Pairs according to Relative Motion between links
(a) Turning Pair
(b) Sliding Pair
(c) Rolling Pair
(d) Screw Pair
(e) Spherical Pair
(2) Kinematic pair According to Nature of Contact
(a) Lower Pair
(b) Higher Pair
(3) Kinematic pair According to Mechanical construction
(a) Closed Pair
(b) Open (Forced-closed) Pair
(ii) 1 cm = 10cm
 DA = 2cm
CB = AB = 3cm
DC = 5cm
2 B
A I23
I12 3
1
D 60°
I34
I13 I14 4 C
NAD = 100 rpm
  100
VAD = VA  AD  AB  0.2  2 
60
= 0.2 × 10.472
VA = 2.094 m/s
By angular velocity ratio theorem
3 I13 I14
1 = I I
13 34
5.8
 3 =  10.472
11.4
3 = 5.328 rad/s (clockwise)
velocity of point B, VB =  BC  3
= 0.3 × 5.328
= 1.59 m/s
Poutput
 = 0.70 
Pinput
Mains Exam
Solution
T3  3
0.70 = T  
1 1
0.70  50  5.328
T3 =
10.472
T3 = 17.81 N.m
i.e. resisting torque = 17.81m
Q.1: (d) (i) The tension T in the spring as shown in the figure given below can be assumed to be
constant for small displacements. Determine the natural frequency of the vertical
vibrations of the spring and also show that the period of vibration is greatest when
a = b: [6 Marks]
T
T
x
1 2
m
b a
(ii) A vibrating system has the following constants:

W = 19.62 kg, K = 8 kg/cm, C = 0.08 kg-s/cm
Determine
(1) damping factor;
(2) natural frequency of damped oscillations;
(3) logarithmic decrement.
Here, W = Weight of mass
K = Spring stiffness
C = Damping coefficient [2 × 3 = 6 Marks]
Sol. (i) 1 2
T T
T sin 1 T sin 2
For small vibration, tan   , sin   , cos   1

x x
1 = and 2 
b a
In equilibrium,

T sin 1  Tsin 2 = mx
T

x  sin 1  sin 2  = 0
m
Mains Exam
Solution
 T  1 1
x    x = 0
mb a
 Natural frequency,
T a  b
n =
m ab
Period of vibration
2 m  ab  4abm
TP =  2 
n T a  b T a  b
Since AM  GM
ab
  > ab
 2 
(a + b)2  4 ab
If a = b, AM = GM
Hence TP will be greatest at a = b
(ii) mass (m) = 19.62 kg
8  9.81
K = 8kg/cm= N/m = 7848 N/m
10 2
0.08  9.81N  s N s
C = 2
 78.48
10 m m
(1) Damping factor   
C C
= n   
2m 2 km
78.48
 =  0.1
2 7848  19.62
(2) Natural damped frequency (d)
d =  
1  2 n
k 7848
where n =   20rad/sec
m 19.62
d = 1   0.1 2  20  19.899 rad/sec
(3) Logarithmic decrement   
 x  2  2  0.1
log  n  =     0.6314
 xn1  1  2
1   0.12
 = 0.6314
Q.1: (e) Differentiate between ‘shaft’ and ‘axle’. A solid shaft of diameter d is used in power
transmission. Due to the modification of existing transmission system, the solid shaft is
required to be replaced by a hollow shaft of the same material and equally strong in
Mains Exam
Solution
torsion. The weight of the hollow shaft per unit length is to be half of the solid shaft.
Determine the outer diameter of the hollow shaft in terms of d. [12 Marks]
Sol. Axle Shaft

Axle is non rotating member. Shaft is rotating member.
Primary fnctino is to provide support to elements Primary functino is transmit torque.
like wheel, pullye etc.
Axle is primarily subjected to bending (axial force) shaft is subjected to bending, torque, as well as
vibrations.
Design of axle is relatively simple compared to Design of shaft is comlex as compared axle
shaft. because shaft is simultaneously subjected to
torque, bending, and vibrations
Depending upon loading condition, cross sectional Cross sectional area of shaft is generallyh circular
area of axle can be different e.g. Rectangular, because it causes minimum vibrations and stres as
Circular, I-section, T-section etc. comopared to other shapes of same cross sectional
area.
e.g. Axles of automobiles, railway buggies. e.g. Shaft fo elecric motor, shaft of IC engine.
Given,
Diameter of solid shaft = d
Weight of solid shaft per unit length W s

Ws =  d2  1    is weight per unit volume 
4
and that of Hollow shaft = W H

WH =   D20  Di2   1 
4
1
According to question, WH = Ws
2
 1  2
   D20  Di2    =  d 
4 2 4
1 2
 D02  Di2 
2
d = ...(i)
 The shafts are required to transmit same power

i.e. Polar section modulus will be same
 J  J
   =  
 r solid  r hollow
  D0  Di 
4 4
d4
 =
d 32 D0 /2
32 
2
1 D0
 = D4  D4
d3 0 i
1 D0
= 2
d3  2 
D04   D02  d 
 2 
Mains Exam
Solution
1 D0
 =
d3  4 
D04  D04  d  D02d2 
 4 
1 4D0
 =
d 4D20  d2
 4D20  d2 = 4dD0
 4D20  4dD0  d2 = 0
4d  16d2  16d2
D0 =
8
d d
 D0 =   0.5d  0.707 d
2 2
D0 = 1.207d
Q.2: (a) The turbine rotor of a ship has a mass of 3000 kg. It has a radius of gyration of 0.45 m
and a speed of 2000 r.p.m. clockwise when looking from stern. Determine the gyroscopic
couple and its effect on the ship—
(i) when the ship is steering to the left on a curve of 100 m radius at a speed of 30 km/
hr;
(ii) when the ship is pitching in a simple harmonic motion, the bow falling with its maximum
velocity. The period of pitching is 40 seconds and the total angular displacement
between the two extreme positions of pitching is 12 degrees. [20 Marks]
Sol. Given
Mass of rotor (m) = 3000 kg
Mass of moment of inertia of rotor (I) = mrG2
where rG = 0.45m
I = 300 × (0.45)2 = 607.5 kg-m2
2N 2  2000
 =   209.439 rad/sec
60 60
(i) When ship steering to left
5
30   m/sec 
V 18
p =   0.0833 rad/sec
R 100
Gyroscopic couple (C) = IP
= 607.5 × 209.439 × 0.0833

C = 10602.84 N-m
Effect
P Active Reactive Bow will move up

couple couple and stern will move
down

Mains Exam
Solution
(ii) When Ship is Pitching:
12
=6°
2
12°
2 2
n =   0.157
T 40
SHM = 6°
SHM velocity of pitching
d
P = where   0 sin t t
dt
P = 0 n cos  n  t 
For maximum pitching velocity t = 0

P = 0.157  6
180
= 0.0164493 rad/sec
Gyroscopic couple (C) = IP

= 607.5 × 209.439 × 0.0164493
C = 2092.91 N-m
Effect

Active Reactive Ship will move

couple couple towards left direction
P
Q.2: (b) A steel cantilever of length 2 m of circular cross-section, 50 mm in diameter, carries

uniformly distributed load of intensity w. What is the maximum value of w so that deflection
at free end is not to exceed 1 mm? Find out the slope at free end. Take E = 200 GPa.
[20 Marks]
x
w N/m
Sol.
x
x
length of beam = 2 m
Diameter of beam, d = 50 mm
Intensity of UDL = w
Maximum allowable deflection of free end = 1 mm
B = ?
E = 200 GPa = 2  105 N mm 2
Mains Exam
Solution
x  x x 2
Bending moment at section X-X (Mx) = 
2 2
using double integral theorem.
d2 y x 2
EI = Mx  x 
dx 2 2
Integrating w.r.t.x
dy x 3
EI =  C1
dx 6
x 4
EI  y  =  C1x  C2
24
Boundary condition
(i) at x = L, y = 0
dy
(ii) at x = L, 0
dx
So, from boundary condition
L3 L4 L4 L4

C1 =  ,C2    
6 24 6 8
x 4 L3 L4
EI(y) =  x
24 6 8
 4
We know that, Moment of inertia, I = d
64

I =  50 4  306.796  10 3 mm4
64
At x = 0, y = ymax = 1mm
L4 w   2000  4
ymax = 1  =
8EI 8  2  105  306.796  103
= 0.0307 N/mm = 30.7 N/m
Also, slope at free end of cantilever, at x = 0,
wl 3 0.0307  2000 3
dy/dx = B =   0.667  10 3 rad
6EI 6  2  105  306.796  10 3
Q.2: (c) A thick cylinder is subjected to both internal and external pressure. The internal diameter
of the cylinder is 200 mm and the external diameter is 250 mm. If the maximum permissible
stress is 30 N/mm2 and the external pressure is 8 N/mm2, determine the intensity of internal
radial pressure. [20 Marks]
Sol. Given: Thick cylinder,
Internal pressure, P1 = ?
External Pressure, P2 = 8 N/mm2
Internal radius, r1 = 100 mm
External radius, r2 = 125 mm
Mains Exam
Solution
Maximum Permissible stress, P =    30N mm2

From Lame’s equation
B
radial stress, r = A ..(i)
r2
B
and hoop stress,   = A ...(ii)
r2
B.C are : r = r1  r  P1 and r  r2  r  P2
 From equation (i), we get
B B
–P1 = A  2
and  P2  A  2
r1 r2
1 1  r 2  r2 
P1  P2 = B  2  2   B  2 2 21 
 r1 r2   r1 r2 
r12r22 P1  P2 
 B =
r22  r12
B r22  P1  P2 
and A = P1  r 2  P1  r 2  r 2
1 2 1
P1r22  P1r12  r22P1  r22P2

= r22  r12
P1r12  P2r22
= r22  r12
Now, eqn. (2), gives
P1r12  P2r22 r12r22  P1  P2  1
 =   2
r22  r12 r22  r12 r
Since hoop stress is maximum at r = r1, so
P1  100 2  8  125 2 100 2  125 2  P1  8  1

30 =  
125 2  100 2 1252  100 2 100 2
 30  5625 = 10000P1  125000  15625P1  125000
25625P1 = 418750
P1 = 16.34 N/mm2
Q.3: (a) A horizontal gas engine running at 200 r.p.m. has a bore of 200 mm and a stroke of 400
mm. The connecting rod is 900 mm long and the reciprocating parts weigh 20 kg. When
the crank has turned through an angle of 30° from the inner dead centre, the gas pressures
on the cover and the crank sides are 500 kN/m2 and 60 kN/m2 respectively. The diameter
of the piston rod is 40 mm. Determine—
(i) Turning moment on the crankshaft;
(ii) Thrust on the bearings;
(iii) Acceleration of the flywheel which has a mass of 8 kg and radius of gyration of 600
mm while the power of the engine is 22 kW. [20 Marks]
Mains Exam
Solution
Sol. 30°
P1
P2
L
r =  200mm L is stroke 
2
L 900 2N
n =   4.5,    20.943 rad/sec
r 200 60
sin  sin30
sin =  sin  
n 4.5
 = 6.379°
(i) Pressure force on piston (FP)
FP = P1A1 – P2(A1 – AP)
 2 
= 500   (0.2)  60  (0.2)2  (0.04)2 
4 4
= 13.898 kN
(ii) Inertia force on piston (FI)
2 cos2 
FI = mrecir  cos  
 n 
2 cos60 
= 20  0.2   20.943  cos 30 
 4.5 
FI = 1.714 kN
(iii) Gravity force due to weight of cylinder (Fg)
Since gas engine is horizontal so Fg = 0
Total force on piston (F) = FP – FI
F = 13.898 – 1.714
F = 12.184 kN
(i) Turning moment on crank shaft (Tr)
F  sin     
Ft =
cos 
F  sin       r 12.184  0.2  sin  30  6.37 
Tr = 
cos  cos  6.37 
Tr = 1.454 kN-m
(ii) Thrust load on bearings (FTh)
F cos     
FTh =
cos 
12.184  cos  30  6.37 

=
cos  6.37 
FTh = 9.87 kN
Mains Exam
Solution
(iii) Acceleration of fywheel (  )
Power  60 22  103  60
Tmean =   1050.42N  m
2N 2  200
T = I where T  T  Tmean
1454 – 1050.42 = mrG2   where,  is angular acceleration of flywheel
403.58 = 8   0.6 2  
 = 140.132 rad/sec 2
Q.3: (b) An epicyclic gear consists of three gears A, B and C as shown in the figure given below.
The gear A has 72 internal teeth and gear C has 32 external teeth. The gear B meshes with
both A and C and is carried on an arm EF which rotates about the centre of A at 20 r.p.m.
If the gear A is fixed, determine the speed of gears B and C: [20 Marks]
E B
C
A
Sol. Distance between centre of gear C and inner edge of gear A is given by
rC  2rB = rA
mT
We know r = assuming module of all gear is same.
2
So TC + 2 TB = TA
32 + 2 TB = 72
T B = 20
arm C(32) B(20) A(72)

32 32 20
Speed 0 x x  x  
20 20 72
8 4
Speed y yx yx y x
5 9
Given NA = 0
4
y x = 0  9y= 4x ...(i)
9
y = 20 rpm (Given)
9y 9  20
x =   45
4 4
Mains Exam
Solution
Speed of gear B (NB)

8 45  8
NB = y  x  20   52rpm
5 5
Negative sign show that B is rotating in opposite direction as that of arm rotation.
Speed of gear (NC)
NC = y + x
NC = 20 + 45 = 65 rpm
In same direction as rotation of arm
Q.3: (c) A single-cylinder reciprocating engine has a speed of 300 r.p.m., stroke 300 mm, mass of
reciprocating parts 50 kg, mass of revolving parts at 150 mm radius 37 kg. If two-thirds of
the reciprocating parts and all the revolving parts are to be balanced, find—
(i) the balance mass required at a radius of 300 mm;
(ii) the residual unbalanced force when the crank has rotated 60° from top dead centre.
[10 Marks]
Sol. Rotating mass (mr) = 37 kg

Reciprocating mass (mreci) = 50 kg
300
r =  150mm
2
2
Mass need to balanced (mun) =  50  37  70.33 kg
3
(i) Balance mass required: (mbal)

For dynamic balancing couple of both system should be same i.e.
mun × rcrank = mbal × rbalance
70.33 × 0.15 = mbal × 0.3
mbal = 35.165 kg
(ii) Residual unbalance force
Horizontal unbalance force (FH) = 1  C  mr2 cos 
2
Where C = ,   60
3
2
 2  2  300   cos 60
FH =  1    50  0.15  
 3  60 
FH = 1233.7 N
Vertical unbalance force (Fv) = cmr2 sin 
2
2 2  300 
=  50  0.15     sin60
3  60 
F v = 4273.667 N
Total unbalance force (Fun) = FH 2  FV 2

Fun = 4448.17N
Mains Exam
Solution
Q.3: (d) Draw the shear force and bending moment diagram for the cantilever beam as shown in
the figure below: [10 Marks]
20 kN 40 kN 20 kN
C
A B
2m
3m
Sol. Sign Convections

For shear
20 kN 40 kN 20 kN
C
+ve –ve A B
For BM 1m 2m
+ve –ve
20 kN 40 kN 20 kN/m
Shear force at ‘A’
VA = – 20 kN
C
A 1m B 2m
Shear force just before ‘B’ = – 20 – 20 ×1 = – 40 kN
Shear force just after ‘B’ = – 20 – 20 × 1 – 40 = – 80 kN
Shear force at ‘C’ = – 20 – 20 × 3 – 40 = – 120 kN 20 kN
And
(–)
Bending moment at ‘A’ = 0 {Free end} 40 kN SFD
1 80 kN
Bending moment at ‘B’ = 20  1  20  1  30 kN  m
2
120 kN
3
Bending moment at ‘C’ = 20  3  40  2  20  3 
2
30 kN-m
BMD
= – 230 kN-m
Parabolic 230 kN-m
Q.4: (a) (i) Describe angular contact bearings and taper roller bearings with the help of neat
sketches. Also, cite at least two advantages and two disadvantages of each.
[8 Marks]
(ii) A pair of spur gears with 20° full-depth involute teeth consists of a 20 teeth pinion
meshing with a 41 teeth gear. The module is 3 mm while the face width is 40 mm. The
material for both the pinion and the gear is steel having an ultimate tensile strength
of 660 N/mm2. The gears are heat-treated to a surface hardness of 400 BHN. The
Mains Exam
Solution
pinion rotates at 1500 r.p.m. and the service factor is 2.0. Assume that the velocity
factor accounts for the dynamic load and the factor of safety is 1.5. Determine the
rated power that the gears can transmit. Assume a Lewis form factor of 0.32.
[12 Marks]
Sol. (i) Angular Contact Bearing: In angular contact bearing, the grooves in inner and outer races are
so shaped that the line of reaction at the contact between balls and races makes an angle
with the axis of the bearing. This reaction has two components angular contact bearing can
take radial and thrust loads.
Advantages:
(a) Angular contact bearing can take both radial and thrust loads.
(b) In angular contact bearing, one side of the groove in the outer race is cut away to permit the
insertion of larger number of balls than that of deep groove ball bearing. This permits the bearing to carry
relatively large axial and radial loads. Therefore, the load carrying capacity of angular contact bearing
is more than that of deep groove ball bearing.
Disadvantags:
(a) Two bearings are required to take thrust load in both directions
(b) The angular contact bearing must be mounted without axial play.
Taper Roller Bearing: The taper roller bearing consists of rolling elements in the form of a frustum of
cone. They are arranged in such a way that the axes of individual rolling elements intersect in a common
apex point on the axis of the bearing. In kinematics analysis, this is the essential requirement for pure
rolling motion between conical surfaces. In taper roller bearing, the line of resultant reaction through the
rolling elements make an angle with the axis of the bearing. Therefore, taper roller bearing can carry both
radial and axial loads.
Roller
Outer race or cup

Iner race or cone
Advantages:
(a) Taper roller bearing can take heavy radial and thrust loads.
(b) Taper roller bearing has more rigidity
Disadvantages:
(a) It is necessary to use two taper roller bearings on the shaft to balance the axial force.
(b) It is necessary to adjust the axial position of the bearing with pre-load. This is essential to coincide
the apex of the cone with the common apex of the rolling elements.
Mains Exam
Solution
(ii) Given:  = 20° full depth involute teeth

TP = 20, TG = 41, m = 3mm, b = 40mm
ut = 660 N/mm2, BHN = 400, NP = 1500 rpm, Cs = 2, fos = 1.5

Lewis form factor, y = 0.32
dP = mTP = 3 × 20 = 60 mm
Since both pinion and gear are made of same material, so design is done on the basis of pinion gear
as it is weaker.
dPNP
Velocity of pinion, V =  4.71ms 1  10 ms1
60  103
3 3
So Cv =   0.389
3  V 3  4.7
660
Beam strength, Sb = mbb y  3  40   0.32  8448N
3
Wear strength, Sw = bQdPK
2
 2Tg   BHN 
= b  T  T   dP  0.16   
 g P   100 
2
 2  41   60  0.16  400 
= 40     
 41  20   100 
= 8259.147 N
Since beam strength is lower than wear strength, So design is done on basis of beam strength
Cs Cs 2T 2 2T
Effective load on tooth, Peff = C Pt  C  d  0.389  0.06  171T Newton
v v P
 In order to avoid failure of tooth in bending,

Sb = Peff × FOS
8259.147 = 171 T × 1.5
 T = 32.199 Nm
32.199  2  1500
P = T   5057.87 watt
60
Q.4: (b) What advantages do the welded joints offer in comparison to riveted joints? Neatly sketch
the basic symbols used to specify the following types of weld:
(i) Fillet
(ii) Square butt
(iii) Single V-butt
(iv) Spot
(v) Seam
(vi) Projection
A beam of rectangular cross-section is welded to a support by means of fillet welds as
shown in the figure given below. Determine the size of the welds if the permissible shear
stress is 80 N/mm2: [20 Marks]
Mains Exam
Solution
30 kN
500
150
100
Sol. Welded joints offer the following advantages compared with riveted joints:
(i) Riveted joints require additional cover plates, gusset plates, straps, clip angles and a large
number of rivets, which increase the weight. Since there are no such additional parts, welded
assembly results in light weight construction. Welded steel structures are lighter than corresponding
iron castings lighter than the corresponding iron castings by 50% and steel castings by 30%.
(ii) Due to the elimination of these components, the cost of welded assembly is lower than that of
riveted joints.
(iii) The design of welded assemblies can be easily and economically modified to meet the changing
product requirements. Alternations and additions can be easily made in the existing structure by
welding.
(iv) Welded assemblies are tight and leakproof as compared with riveted assemblies.
(v) The production time is less for welded assemblies.
(vi) When two parts are joined by the riveting method, holes are drilled in the parts to accommodate
the rivets. The holes reduce the cross-sectional area of the members and result in stress
concentration. There is no such problem in welded connections.
(vii) A welded structure has smooth and pleasant appearance. The projection of rivet head adversely
affects the appearance of the riveted structure.
(viii) The strength of welded joint is high. Very often, the strength of the weld is more than the strength
of the plates that are joined together.
(ix) Machine components of certain shape, such as circular steel pipes, find difficulty in riveting.
However, they can be easily welded.
Type of Weld Symbol

Fillet
Square Butt
Single V-Butt
Spot
Seam
Projection
Basic Weld Symbols
The primary shear stress in weld is given by
P 30000 60
1 =   N/mm2
A 2 100t  150t  t
Mains Exam
Solution
The bending moment Mb is given by

Mb = Pe = 30000 × 500 = 15 × 106 Nmm
The polar moment of inertia of all welds about axis of bending i.e. x -axis
1503 t  2
 150  100  t  
3
lxx 2
=  12  100t    
   2  12  
Since t is less compared to length so
1503 t 2
 150  
Ixx = 2   100t   
 12  2  
= 75 × 1502 t mm4
Therefore, the bending stress b is given by
Mb  r 15  106  75
b = 
I 75  1502 t
666.66
= N/mm2
t
The minimum shear stress in the weld is given by
2 2 2
 b   666.66   60 
 12  
 =   
2  2t   t 
338.69
= N / mm2
t
Since the permissible shear-stress in the weld is 80 N/mm2
338.69
80 = N/mm2
t
338.69
t =  4.23mm
80
Leg length of the weld
t
h =  5.98  6 mm
0.707
Q.4: (c) A shaft is subjected to a maximum torque of 10 kN-m and a maximum bending moment
of 7.5 kN-m at a particular section. If the allowable equivalent stress in simple tension is
160 MN/m2, find the diameter of the shaft according to (i) maximum shear stress theory,
(ii) strain energy theory and (iii) shear strain energy theory. Take Poisson’s ratio as 0.24.
[20 Marks]
Sol. Given
Torque, T = 10 kN-m
Bending moment, M = 7.5 kN-m
Allowable equivalent stress in simple tension = 160 MN/m2 = 160 N/mm2
Poisson’s ratio = 0.24
Let the diameter of shaft be ‘D’ mm.
Mains Exam
Solution
(i) Maximum shear stress theory

According to this theory,
 fy  1
max    
 2  FOS
1  2  fy 
max =  
2 2
16 M  M2  T 2  M  M2  T 2  160
  
D3 2 2
16 7.5  7.52  102  7.5  7.52  102 

  3
 106  80
D 2
 D  116.75 mm
(ii) Strain energy theory:
According to this theory
2
 fy 
12  22  2 12   
 FOS 
2 2
 16   2 2  f 
  3
 M  M2  T 2   M  M2  T2   2  0.24  M  M2  T2   M  M2  T2     y 
 
 D  
 
  FOS 
2
 16  2 2
  3   7.5  7.52  102
    7.5  7.52  102 
 D 

2  0.24  7.5  7.52  102  7.5  7.52  102   1012  160 2
 D  88.46 mm
(iii) Shear strain energy theory
According to this theory,
2
12  22  12   fy 
 FOS 
2 2
 16   2 2  fy 

  3    M  M2  T 2   M  2 2   M  M  T    
2 2 2
 D  M T   FOS 
2
 16   2 2
  7.52  7.52  102    10  160 
12 2
 
 3    7.5  7.52  102
 D 
   7.5  7.52  102 
 D  90.01 mm
Mains Exam
Solution
SECTION–B
Q.5: (a) Describe the following microconstituents of iron-carbon alloys in relation to the phases
present, arrangement of phases and their relative mechanical properties: [12 Marks]
(i) Spheroidite
(ii) Pearlite
(iii) Bainite
(iv) Martensite
Sol: (i) Spheroidite: If a steel alloy having either pearlitic or bainitic microstructures is heated to and left
at, a temperature below the eutectoid for a sufficiently long period of time –for example, at about
700°C (1300°F) for between 18 and 24 h–yet another microstructure will form. It is called spheroidite.
Instead of the alternating ferrite and cementite lamellae (pearlite), or the microstructure observed
for bainite, the Fe3C phase appears as sphere-like particles embedded in a continuous  phase
matrix.
There is less boundary area per unit volume in spheroidite, and consequently plastic deformation
is not nearly as constrained, which gives rise to relatively soft and weak material. In fact, of all
steel alloys, those that are softest and weakest have a spheroiditie microstructure.
As would be expected, spheroidized steels are extremely ductile, much more than either fine or
coarse pearlite. In addition, they are notably tough because any crack can encounter only a very
small fraction of the brittle cementite particles as it propagates through the ductile ferrite matrix.
(ii) Pearlite:
Cooling
Austenite 
 Ferrite 0.02%C   Cementite  6.67%C 
 0.77%C  Heating
In the reaction, the simultaneous formation of ferrite and cementite from austenite results at the
temperature of 723°C and composition of 0.80% carbon. There are nearly 12% of iron carbide
and slightly more than 88% of ferrite in the resulting mixture. Since the ferrite and cementite are
formed simultaneously, they are intimately mixed. Characteristically, the mixture is lamellar, i.e. it
is composed of alternate layers of ferrite and cementite. This mocrostructure is called pearlite,
which is very important in iron and steel technology, because it can be formed in almost all steels
by mean of suitable heat treatments.
(iii) Bainite: The microstructure of bainite consists of ferrite and cementite phases, and thus diffusional
processes are involved in its formation. Bainite forms as needles or plates, depending on the
temperature of the transformation. Because bainitic steels have a finer structure (i.e., smaller
  ferrite and Fe3C particles), they are generally stronger and harder than pearlitic ones; yet they
exhibit a desirable combination of strength and ductility.
(iv) Martensite: Martensite has a body centered tetragonal (BCT) structure. As martensite has few
slip systems (along which dislocation moves) as compared to BCC structure, it is extremely hard
and brittle. It lacks toughness and has negligible ductility. Martensite is formed when austenitezed
iron carbon alloys are rapidly cooled (or quenched) to a relatively low temperature (in the vicinity
of the ambient). Martensite is a nonequilibrium single phase structure that results from a diffusionless
transformation of austenite.
Q.5: (b) In an orthogonal cutting operation, the cutting speed is 2.5 m/s, rake angle is 6° and the
width of cut is 10 mm. The undeformed chip thickness is 0.2 mm. 13.36 grams of steel
chips with total length of 50 cm are obtained. The tool post dynamometer gives cutting and
thrust forces as 1134 N and 453.6 N respectively. Find—
Mains Exam
Solution
(i) shear plane angle;

(ii) friction energy at tool-chip interface as percentage of total energy;
(iii) specific cutting energy.
Assume density of steel = 7.8 grams/cm3. [12 Marks]
Sol. Given that,

Cutting speed, V = 2.5 m/s
Rake angle,  = 6°
Width of Cut, b = 10 mm = 10 2 m
Underformed chip thickness, t = 0.2 mm
Mass of steel chips, m = 13.36 grams
Total length of chip, l = 50 cm = 0.5 m
Cutting force, FC = 1134 N
Thrust Force, Ft = 453.6 N
Density of steel, l = 7.8 gm/cm3
Let chip thickness = tC
 Mass = Density × Volume
m =   l  b  tC
13.36 = 7.8  50  10  10 1  t C
tC = 0.0342cm  0.342mm
t
Chip thickness ratio, r = t
C
0.2
=  0.584
0.342
(i) Shear plane angle, (  )
r cos 
tan =
1  r sin 
0.584  cos6
tan =  0.618
1  0.584  sin6
 = tan1  0.618   31.739

(ii) Friction Force (F)
F = FC sin   Ft cos 
F = 1134  sin 6  453.6  cos 6   569.65N

Shear force (FS)
FS = FC cos   Ft sin 
FS = 1134  cos 31.739  453.6  sin31.739

= 725.79 N
Mains Exam
Solution
Total Energy = Friction Energy + Shear Energy

FC × V = F  VC  FS VS ...(i)
V sin 
Chip Velocity, VC = cos
  
2.5  sin31.739
VC =  1.459m s
cos  31.739  6 
Friction energy as percentage of total energy,
F  VC
= F  V  100%
C
569.65  1.459
=  100%
1134  2.5
= 29.33%
FC 1134
(iii) Specific cutting energy, E =   0.567 J mm3
1000bd 1000  10  0.2
Q.5: (c) Describe four tests of flexibility that an automated manufacturing system should satisfy to
qualify as being flexible. Also list the application areas where FMS technology is successfully
employed. [12 Marks]
Sol. Test of flexibility : To quality as being flexible, a manufacturing system should satisfy several criteria.
The four following test of flexibility in an automated manufacturing system are :
1. Part Variety Test: Can the system process different part styles in a nonbatch mode ?
2. Schedule Change Test: Can the system reading accept changes in production schedule, and
changes in either part mix or production quantity.
3. Error recovery Test: Can the system recover quickly from equipment break downs, so that the
production is not completely distrupted
4. New part Test: Can new part designs introduced into the existing product mix with relative ease.
If the answer of all these question is “yes” for a given manufacturing system, the system can be
considered flexible.
 The most effective FMS applications are in medium quantity batch production. When a variety of
parts is to be produced, FMS is suitable for production quantities typically upto 15000 to 35000
aggregate parts/year. Most of the experience in FMS has been gained in machining applications.
Q.5: (d) Describe at least five main functions carried out by coating on electrode in electric arc
welding process. Also, list the constituents of coating and their purpose. [12 Marks]
Sol: Electrode coating and its functions: Coating or cover on the electrode core wire is provided with
various hydrocarbon compound and elements to perform specific roles as discussed later in the following
text. But the important function of providing arc shielding is of prime interest.
The important functions are as under:
(i) Improve the electric conductivity in the arc region to improve the arc ignition and stabilization of
the arc.
(ii) Slag formation influences size of molten metal droplet, protects the droplet during transfer and
weld pool from atmospheric gases.
Mains Exam
Solution
(iii) Provide deoxidizers like Si and Mn, alloying elements such as Cr, Ni, Mo to improve weld metal
properties.
(iv) Improve metal deposition rate with addition of iron powder in coating.
(v) Controlled alloying of the weld metal to achieve specific properties can be done by incorporating
required alloying elements in electrode coatings.
Coating Constituent Function
Cellulose Gas former

Calcium Fluoride (CaF 2) Slag basicity and metal fluidity, H 2 removal
Clay (Aluminum Silicate) Slag former
Talc (Magnesium Silicate) Slag former
Rutile (TiO2) Arc stabilizer, Slag former, Fluidity
Iron Oxides Fluidity, Slag former
Calcium Carbonate Gas former, Arc stabilizer
Asbestos Coating strength
Quartz (SiO 2) Slag fluidity, Slag former
Sodium Silicate/Potassium Silicate Binder, Arc stabilizer
FeMn / FeSi Deoxidizer
Iron Powder Deposition Rate
Powdered Alloys Alloying
Q.5: (e) Explain the distinction between the following using block diagrams and examples:
[6+6 Marks]
(i) Measurement systems and Control systems
(ii) Open-loop systems and Closed-loop systems
Sol: (i) Measurement systems: A fundamental part of many mechatronics system is a measurement
system used for making measurements.
Figure given below indicates the functional elements of an instrument by various blocks.
Input Variable
Physical variable Primary sensing
conversion
to be measured Signal element
element
Data Data Data Variable

Observer presentation processing transmission manipulation
element element element element
As an example, consider a thermocouple-based digital temperature measurement system shown in

figure below:
Amplifier
Thermocouple LED display
A/D and display decoder
Transducer Signal processor Recorder

Figure: Measurement system
Mains Exam
Solution
Control systems:
Error
detector
Error Servo motor Output
Controller load
Set point signal
Sensor for table

movement
Fig. Block diagram representing closed-loop control system

As an example temperature control in a Metal-melting furnace
To chimney
Pressure
gauge
Furnace
Burner
Oil
Actuator
Air
Furnace pressure control system
(ii) Open-loop systems and Closed-loop systems

Open-loop control systems
A good example of an open-loop control system is shown in Figure. The input signal or command signal
is given to the machine tool to perform the required machining operations. The tool moves with respect
to a command signal given by the operator. There is no return signal to verify whether the tool has
moved to the correct position or not (this is why it is called non-feedback or open-loop system). Thus,
the error is not found and therefore, not corrected. E.g. Traffic Light Signal
Set point Stepping Output

Controller motor
or input
Fig. Block diagram representing an open-loop system
Closed-loop control systems

The input signal is given to the machine and the table moves. The feedback device (transducer) is
connected to the table, which senses the movement and positions the table. After sensing, the transducer
converts this mechanical movement into an electrical signal. This electrical signal is then fed to the error
detector device for comparison with set value or reference value called an error signal (error is the
difference between the measured output to the set value). Then, this error signal is sent to the controller
for rectifying the error by operating the servo motor. E.g. Temperatgure control in refrigeration system
Mains Exam
Solution
Error
detector
Error Servo motor Output
Controller load
Set point signal
Sensor for table

movement
Fig. Block diagram representing closed-loop control system
Q.6: (a) (i) In an open die forging, a strip 150 mm wide, 4 mm long and 10 mm thick is compressed
in plane strain such that the dimension 400 remains same. The yield strength of
material in uniaxial compression is equal to 200 N/mm2. Find the minimum, average
and maximum die pressures at the beginning of plastic deformation if the coefficient
of friction on the interface between the die and the material is equal to 0.1.
[10 Marks]
(ii) For a product, the purchase prices are given below:
Sl. No. Order quantity (Qi ) Unit prices ( ` )

1 Q1  500 10.00
2 500  Q2  750 9.25
3 Q3  750 8.75
Determine the optimum purchase quantity if the annual demand of the product is 2400
units. The cost of ordering is ` 100 and the inventory carrying charge is 24% of the
purchase price per year. [10 Marks]
Sol. (i)
b 150
Length of outer edge from centre of strip (L) =  = 75 mm
2 2
h  1 
Sticking zone length, (xs) = L  2 n  2 
 
10  1 
xs = 75  n  
2  0.1  2  0.1 
xs = –5.47 (so there is only sliding zone)
Sliding zone 0  x  75 mm .
Pressure variation in sliding zone is given by

2
(L  x)
P = 2ke h
Maximum pressure at x = 0 i.e.,
2
L
Pmax = 2ke h
y
where k = (From von mises theory)
3
200
k = = 115.47 N/mm2
3
Mains Exam
Solution
20.1
75
Pmax = 2  115.47 e 10 = 1035.00 N/mm2
Pmax  1035 N / mm2

Minimum pressure is at x = L, i.e.
Pmin = 2ke = 2k = 230.94 N/mm2
Pmin  230.94 N / mm2

Mean pressure (Pmean):
L
Pmean × L = o P dx
2
75 (L  x)
Pmean × 75 = 0 2ke h
= 40203.06
Pmean  536.04 N / mm2
(ii) Annual Demand D = 2400

Ordering cost per order C0 = ` 100
Carrying cost per unit per year, Cc = 0.24
Where p = purchasing price per unit
Case-I: When Q < 500, p = 10

2DC0 2  2400  100
EOQ =   447.2  447
Cc 0.24  10
 Total cost per year
TC1 = p  D  2DC0Cc
= 10  2400  2  2400  100  0.24  10
= ` 25073.3
Case-II When 500  Q  750, p  9.25
2DC0 2  2400  100

 EOQ =   465
Cc 0.24  9.25
This is not feasible
Case-III: When Q  750, p  8.75
2DC0 2  2400  100

EOQ =   478
Cc 0.24  8.75
This is not feasible
Total cost per year at Q = 500,
D Q
Tc2 = p  D   C0   Cc
Q 2
2400 500
= 9.25  2400   100   0.24  9.25
500 2
= 22200 + 480 + 555 = ` 23235
Mains Exam
Solution
Total cost per year at Q = 750

Q D
Tc3 = p  D   Cc   C0
2 Q
750 2400
= 8.75  2400   0.24  8.75   100
2 750
= 21000 + 787.5 + 320 = ` 22107.5
Out of Tc1, Tc2 and Tc3, the minimum value is for Tc3. Hence the optimum order size = 750
Q.6: (b) What is a eutectoid reaction? Explain the development of microstructure in iron-carbon
alloys of hypoeutectoid, eutectoid and hypereutectoid compositions when they are cooled
from high temperature with the help of neatly labelled diagrams indicating the phases
present. [20 Marks]
Sol. The iron-iron carbide eutectoid reaction is fundamental to the development of pearlite microstructure in
steel alloys.
Cooling

  0.76 wt%C   
   0.022wt%C   Fe3 C  6.70 wt%C  ...(i)
Heating
Development of microstructure in iron-carbon alloys:

Eutectoid: An alloy of eutectoid composition (0.76 wt% C) as it is cooled from a temperature within the
 phase region, say, 800°C–that is, beginning at point a in figure. and moving down the vertical line xx’.
Initially, the alloy is composed entirely of the austenite phase having a composition of 0.76wt% C and
corresponding microstructure, also indicated in figure. As the alloy is cooled, there will occur no changes
until the eutectoid temperature (727°C) is reached. Upon crossing this temperature to point b, the
austenite transforms according to equation (i).
1100
  Fe3C
1000
900
x
Temperature (°C)
800 a
Figure: Schematic representations of the
 727°C microstructures for an iron-carbon
alloy of eutectoid composition (0.76 wt% C)
700 b
above temperature.
600
Fe3C
500   Fe3C
x
400
0 1.0 2.0
Composition (wt% C)
Hypoeutectoid Alloys: Consider a composition C0 to the left of the eutectoid, between 0.022 and 0.76
wt% C; this is termed a hypoeutectoid (less than eutectoid) alloy. Cooling an alloy of this composition
is represented by moving down the vertical line yy’ in figure. At about 875°C, point c, the microstructure
will consist entirely of grains of the  phase, as shown schematically in the figure. In cooling to point
d, about 775°C, which is within the    phase region, both these phases will coexist as in the
Mains Exam
Solution
schematic microstructure. Most of the small  and  phases may be determined using the appropriate
tie line; these compositions correspond, respectively, to about 0.020 and 0.40 wt% C.
1100 P
  Fe3C
1000
z
g
900
Fe3C
Temperature (°C)
Figure: Schematic representations of the

800 microstructures for an iron-carbon
h alloy of hypereutectoid composition
 C1 (containing between 0.76
O i cooled from within the below the
700 eutectoid temperature
Pearlite
600
Proeutectoid
Fe3C Eutectoid
Fe3C
500
  Fe3 C
z
400
0 1.0 2.0
c1
Composition (wt% C)
Hypereutectoid Alloys: Analogous transformations and microstructure result for hypereutectoid alloys,
thsoe containing between 0.76 and 2.14 wt% C, which are cooled from temperature within the  phase
field. Consider an alloy of composition C1 in figure that, upon cooling, moves down the line zz’. At point
g only the  phase will be present with a composition of C1; the microstructure will appear as shown,
having only  grains. Upon cooling into the   Fe3C phase field – say, to point h–the cementite phase
will begin to form along the initial   Fe3C grain boundaries, similar to the  phase in figure point d.
This cementite is called proeutectoid cementite–that wjhich forms before the eutectoid reaction. Of
course, the cementite composition remains constant (6.70 wt% C) as the temperature changes.
1100
1000
y
  Fe3C
M c
900
Temperature (°C)
Figure: Schematic representations

of the microstructures for an
800 d iron-carbon alloy of hypereutectoid
Te e composition C0 (containing less than
N
0.76 wt% the austenite phase region
700 f O
to temperature
Pearlite
600 Fe3C
Proeutectoid 
Eutectoid 
500
  Fe3C
y
400
0 1.0 2.0
Composition (wt% C)
Mains Exam
Solution
Q.6: (c) (i) Describe, with neat sketches, the working principle of—
(1) linear variable differential transformer (LVDT);
(2) Hall effect sensor [5+5 Marks]
(ii) A measurement system consists of a cylindrical load cell of diameter 2.5 mm. The
material of the cell is steel with modulus of elasticity, E = 210 GPa and Poisson’s ratio,
 = 0.3. This carries four strain gauges each with gauge factor 2.1. Two of them are
mounted longitudinal and other two are transverse. The resistances of the gauges are
120  . This load cell is required to yield a voltage through the bridge of strain gauges
with bias 10V. If the maximum load sustained by the cell is –2500 N, what is the
corresponding voltage across the bridge? [10 Marks]
Sol: (i) (1) Linear Variable Differential Transformer (LVDT)

The LVDT is a rugged electromagnetic transducer used to measure linear displacement. LVDT consists
of an iron core which can move freely within a primary or power coil and two secondary coils as shown
in figure. A movable magnetic core provides a variable coupling between windings. The secondary coils
are connected in series configuration and are equally positioned with respect to the primary coil.
When the core is centrally located, the emfs generated in the secondary coils are equal and opposite
and the net output voltage is zero. When the core is moved to one side, the voltage in the primary coil
becomes larger and that in the other secondary coil becomes smaller. The magnitude of output voltage
is proportional to the displacement of the core from the null position. The phase sensitive detector
converts the AC secondary voltage into a DC voltage, V0. The magnitude of the DC voltage is proportional
to the amplitude of the AC voltage.
At the mid-position of the core, the induced voltage in each coil is of the same amplitude and 180º out
of phase, producing a zero or null output. As the core moves from the null position, the output amplitude
increases a proportional amount over a linear range around the null as shown in figure.
Linear range
+ –
Mid-position
Secondary coil 2
Output voltage
of core
– +
Displacement x
Primary coil
0
Left Core displacement Right
b
a
+180º
+
0
Phase-sensitive Displacement
Output voltage V o
detector –180º
f
–
Linear variable differential transformer LVDT output characteristics

(2) Hall effect sensors
When a beam of charged particles passes through a magnetic field, the beam is deflected from its
straight line path due to the forces acting on the particles. A current flowing in a conductor, such as a
beam, is deflected by a magnetic field. This effect is called Hall effect.
Mains Exam
Solution
Output
Hall voltage
strip 2
t
1
Transverse Vi R
magnetic field A
Fig. Hall effect sensor

The working principle of a Hall effect sensor is that if a strip of conducting material carries a current
in the presence of a transverse magnetic field as shown in Fig., the difference of potential is produce
between the opposite edges of the conductor. The magnitude of the voltage depends upon the current
and the magnetic field. The current is passed through leads 1 and 2 of the strip and the output leads
3 and 4 are connecred with a Hall strip. When a transverse magnetic field passes through the strip, the
voltage difference occurs in the output leads. The Hall effect sensor has the advantage of being able
to operate as a switch and it can operate upto 100 kHz.
(ii) Given, diameter of load cell, d = 2.5 mm
E = 210 GPa, Poisson’s ratio,   0.3
Gauge factor, Gf = 2.1
Resistance of each gauge, Rg  120
Supply voltage, Vi = 10V

Load applied, F = 2500 N (Compressive)
load
stress    =
cross-sectional area
2500
=   5.093  108 N/m2
2
  0.0025 
4
stress
strain  =
modulus of elasticity
5.093  108
=  2.425  10 3
210  109
fractional change in resistance,
dR
= Gf   2.1 2.425  103
R
= 5.093 × 10–3
The output voltage of bridge using four strain gauges mounted at 90°
 dR Vi   Vi
V0 = 2 1        2 1    Gf 
 R 4 4
Mains Exam
Solution
= 2 1  0.3   5.093  103  10 / 4 
= 0.033 volt
Q.7: (a) (i) On the basis of microstructure, briefly explain why gray iron is brittle and weak in
tension. Compare gray and malleable cast irons with respect to (1) composition and
heat treatment, (2) microstructure and (3) mechanical properties. [10 Marks]
(ii) Cite three sources of internal residual stresses in metal components. What are two
possible adverse consequences of these stresses? Describe the following heat
treatment procedures for steels and for each, the intended final microstructure:
Full annealing, Normalizing, Tempering and Quenching
[10 Marks]
Sol. (i) Mechanically, gray iron is comparatively weak and brittle in tension as a consequence of its
microstructure; the tips of the graphite flakes are sharp and pointed, and may serve as points of
stress concentration when an external tensile stress is applied. Strength and ductility are much
higher under compressive loads.
This question asks us to compare various aspects of gray and mellable cast irons.
(a) With respect to composition and heat treatment :
Gray iron - 2.5 to 4.0 wt% C and 1.0 to 3.0 wt%. For mass gray irons there is no heat treatment after
solidification.
Malleable iron - 2.5 to 4.0 wt% C and less than 1.0 wt% St. White iron is heated in a nonoxidizing
atmosphere and a temperature between 800 and 900°C for an extended item period.
(b) With respect to microstructure :
Gray iron-Graphite flakes are embedded in a ferrite or pearlite matrix.
Malleable iron - Graphite clusters are embedded in a ferrite or pearlite matrix.
(c) With respect to mechanical characteristics :
Gray iron - Relatively weak and brittle in tension; good capacity for damping vibrations,
Melleable iron - Moderate strength and ductility.
(ii) Three sources of internal residual stresses in metal components are :

1. Plastic deformation process such as machining and grinding
2. Nonuniform cooling of a piece that was cold from an elevated temperature such as in casting or
welding.
3. Phase transformation that is induced upon cooling in which parent and product phases have
different densities.
Two adverse consequences of these stresses are distortion, crack formation and fracture.
Full annealing: Heat to about 50°C above the A3 line, figure 11.10 (fi the concentration of
carbon is less than the eutectoid) or above A1 line (if the concentration of carbon is greater
than the eutectoid) until the alloy comes to equilibriums, then furnace cool to room
temperature. The final microstructure is coarse parlit.
Normalizing: Heat to at least 55°C above the A3 line Figure 11.10 (if the concentration of carbon
is less than the eutectoid) or above the Acm line (if the concentration pf carbon is greater than the
eutectoid) until the alloy completely transform to austenite, then the cool in air. The final
microstructure is file perlite.
Ouenching: Het to a temperature with the austentite phase region and alloy the specimen to fully
austenitize, the quench to room temperature in over water. The final microstructure is martensite.
Mains Exam
Solution
Tempering: Heat is quenched (martensite) specimen to a temperature between 450 and 650°C,
the for time necessary to achieve the desired hardness. The final microstructure is tempered
martensite.
Q.7: (b) (i) Why is unilateral tolerance preferred over bilateral tolerance? Find the limits of tolerance
and allowance for a 25 mm H8d9 shaft and hole pair. The 25 mm shaft lies in the
18–30 diameter step. The fundamental tolerance can be computed using
3
i = 0.45 D  0.001D  m . For H8 hole, the fundamental tolerance is 40i. The fundamental
deviation for the shaft can be computed using –16D0.44  m . What type of fit is given
by H8d9?
List the causes of getting primary texture and secondary texture in machined
components. Further, list the three main methods of assessment of surface texture.
[10 Marks]
(ii) Five jobs are to be processed on three machines. The processing time (in hours) is
given in the following table. Find the optimal schedule so that the total elapsed time
is minimized. Also, find the idle time on each machine: [10 Marks]
Jobs
J1 J2 J3 J4 J5
M1 8 10 6 7 11
Machines M2 5 6 2 3 4
M3 4 9 8 6 5
Sol: (i)
Unilateral tolerance is preferred over bilateral tolerance because of the following reasons:
(a) It is easy and simpler to determine deviations in unilateral tolerance.
(b) Provides flexibility to operator as he has to maintain only lower limit of holes knowing fully that
he still has some margin left for machining before the part is rejected.
Given, 25 H8d9
Basic size = 25mm
Mean dia (D) = 18  30

= 23.24 mm
Tolerance factor (i) = 0.45 D1/3 + 0.001 D
= 0.45 (23.24)1/3 + 0.001 × 23.24
= 1.307 microns
For hole, H fundamental deviation is zero
Fundamental tolerance (1T8),
= 25i
= 25 × 1.307
= 32.675 microns
 0.033 mm
Mains Exam
Solution
For shaft f, fundamental deviation = – 16 D0.44

= –16(23.24)0.44
= – 63.85 microns
= – 0.064 mm
Fundamental tolerance for shaft (IT 9)
= 40i
= 40 × 1.307
= 52.28 microns
= 0.052 mm
For hole,
Upper or high limit = Basic size + Tolerance
= 25 + 0.033
= 25.033 mm
Lower or Low limit = Basic size + 0 = 25 mm
 25 0.033
0.000 mm
For shaft, upper or high limit = Basic size - Fundamental deviation

= 25 – 0.064
= 24.936 mm
Lower or low limit = Basic size – fundamental deviation – tolerance
= 25 – 0.064 – 0.052
= 24.884
 250.064
0.016
0.033mm Zero Line

0.064mm
Hole
25m 24.936mm
Shaft 24.884mm
Datum Line
The figure clearly indicates that the given fit is clearance fit with.
Min (c) = LL of hole – UL of shaft
= 25 – 24.936 = 0.064 mm
Max (c) = UL of hole – LL of shaft
= 25.033 – 24.884 = 0.149 mm
A single-point tool turning a bar. The metal is cut from A to B and from C to D, but the element D to
E is a torn surface created when the tool’s end cutting-edge passes through the wall left on the previous
revolution by its side cutting-edge. Further, in some machining processes the action of the nose from
B to C can be more akin to burnishing than cutting.
Mains Exam
Solution
Thus the roughness on surfaces produced by single point cutting tends to be both uniformly spaced and
directional.
Roughness Waviness
(Primary (Secondary texture)
texture)
Lay
(Direction of dominant
pattern)
Roughness
spacing
Profile
Waviness
spacing
Elements of surface character of

a machined surface
Reasons for
(i) Primary texture Roughness: Small wavelength scratches or tool marks produced by cutting
tools or during other production processes
(ii) Secondary texture (Waviness): Spindle or cutter deflection, machine vibrations, chatter, hard
sports, impertect truing of a grinding wheel etc.
Three main methods to assessment of surface texture:
(i) Optical method using light interference microscopes
(ii) Stylus method using electrical integration.
(iii) Tactile (Finger nail) surface assessment method.
(ii)
Jobs M1 M2 M3
J1 8 5 4
J2 10 6 9
J3 6 2 8
J4 7 3 6
J5 11 4 5
This sequencing problem involves three machines and minimum time on machine M1  maximum
time on machine M2 or minimum time on machine M3  Maximum time on machine M2
Hence, the above problem can be converted into an equivalent two machine problem by two fictions
machines G and H, such that
G = M1 + M2 and H = M2 + M3
Jobs G H
J1 13 9
J2 16 15
J3 8 10
J4 10 9
J5 15 9
Mains Exam
Solution
The smallest value is for job J3 on G.

J3
The reduced set of processing times becomes
Jobs G H
J1 13 9
J2 16 15
J4 10 9
J5 15 9
The jobs J1, J4 and J5 each has same processing tie on machine H, so the job with the lowest time
on machine G is selected first and so on.
J3 J2 J5 J1 J4
So the sequence will be J3  J2  J5  J1  J4
Job Time in Time out Time in Time out Time in Time out
J3 0 6 6 8 8 16
J2 6 16 16 22 22 31
J5 16 27 27 31 31 36
J1 27 35 35 40 40 44
J4 35 42 42 45 45 51
Total lapsed time = 51
Idle time on machine M1 = 51 – 42 = 9
Idle time on machine, M2 = 6 + 8 + 5 + 4 + 2 + 6 = 31
Idle time on machine, M3 = 8 + 6 + 4 + 1 = 19
Q.7: (c) (i) What are natural and forced responses of a dynamic system? Derive the expression
for dynamic natural response of a spring-mass system. [10 Marks]
(ii) A vector 25i + 10j + 20 k is translated by 8 units in X and 5 units in Y directions.
Subsequent to this the vector is rotated by 60° about Z-axis and 30° about X-axis.
Determine the final form of the vector. [10 Marks]
Sol. (i) Natural and forced responses

The term natural response is used for a system when there is no input to the system forcing the variable
to change but it is just changing naturally. As an illustration, consider the first-order system of water
being allowed naturally to flow out of a tank (Fig.)
Cross-sectional area
Cross-sectional area A
A
p1 p1
h h
q q2
p2 p2
(a) (b)
Mains Exam
Solution
For such a system we have

p1 – p2 = Rq
where R is the hydraulic resistance. But p1 – p2 = hg , where  is the density of the water, and q is
dV
the rate at which water leaves the tank and so is , with V being the volume of water in the tank
dt
 d(Ah)  Adh
and so being Ah. Thus q = = and so the above equation can be written as
dt dt
dh
hg = RA
dt
This is the natural response in that there is no input to the system forcing the variable h to change; it
is just naturally changing with time. We can draw attention to this by writing the differential equation with
all the output terms, i.e. h, on the same side of the equals sign and the input term of zero on the right,
i.e.
dh
RA  ( g)h = 0
dt
In the differential equation was derived for a water tank from which water was flowing but also into which
there was a flow of water (Fig.) This equation has a forcing input function of q1 and can be written as
dh
RA  ( g)h = q
dt 1
As another example, consider a thermometer being placed in a hot liquid at some temperature TL. The
rate at which the reading of the thermometer T changes with time was derived in as being given by the
differential equation
dT
RC T = T
dt L
Such a differential equation has a forcing input of TL.

Natural Response of a Spring Mass System (First Order System) :
The input y(t) can take many forms. Consider first the situation when the input is zero. Because there
is no input to the system we have no signal forcing the system to respond in any way other than its
natural response with no input. The differential equation is then.
dx
a1  a0 x = 0
dt
When can solve this equation by using the technique called separation of variables. The equation can
be written with all the x variables on one side and all the t variables on the other.
dx a0
= dt
x a1
Integrating this between the initial value of x = 1 at t = 0, i.e. a unit steip input, and x at t gives
a0
lnx = a t
1
and so we have,
x = e a0 t /a1
Mains Exam
Solution
We could however, have recognised that the differential equation would have a solution of the forms x
= Aest, where A and s are constants. We then have dx/dt = sAest and so when these values are
substituted in the differential equation we obtain.
a1sAest + a0Aest = 0
and so a1s + a0 = 0 and s = –a0/a1. Thus the solution is
x = Ae a0 t/ a1
This is termed the natural response since there is no forcing function. We can determine the value of
the constant A given some initial (boundary) condition. Thus if x = 1 when t = 0 then A = 1. Shown in
figure, the natural response, i.e. an exponential decay:
Output, x
y(t) x(t)
System
Zero
input
0
Time
Fig. Natural response of a first order system
(ii) Homogeneous transformatix after successive translations and rotations :
[T] =  Ttr  Trz 60    Trx  30  
1 0 0 8  cos60 sin60 0 0 1 0 0 0
   
0 1 0 5   sin60 cos60 0 0  0 cos30  sin30 0
   
[T] = 0 0 1 0  0 0 1 0  0 sin30 cos30 0
   
0 0 0 1  0 0 0 1 0 0 0 1
cos 60  sin 60 0 8 1 0 0 0
 sin 60 cos 60 0 5  0 cos 30  sin30 0 

=  0 0 1 0  0 sin30 cos 30 0
  
 0 0 0 1 0 0 0 1
cos60  sin 60 cos30 sin 60 sin30 8

 
 sin60 cos60 cos30  cos60sin30 5
 
=  0 sin30 cos30 0
 
 0 0 0 1
Mains Exam
Solution
 1 3 3 3 1 
    8
 2 2 2 2 2 
 
 3 1 3 1 1
   5
 2 2 2 2 2 
 
=  1 3 
 0 0
2 2
 
 0 0 0 1
 1 3 3 
  8
 2 4 4  25 
   
 3 3 1
 5 10 
 2 4 4   
 T  X

= 
 20 
1 3   
 0 0 1
2 2
 
 0 0 0 1
 25 30 3 
    20  8 
 2 4 4 
 
 25  3  3  10  20  5 
 2 4 4 
 
=  10 3 
 0    20  0 
2 2
 
 0  0  0 1 
 21.66 
 
 25.98 
 
=  22.32 
 
 1 
Final form of vector = 21.66iˆ  25.98ˆj  22.32kˆ
Q.8: (a) (i) Explain briefly the following: [10 Marks]

(1) Four configurations of Robot
(2) Work volume
(3) Spatial resolution
(4) Accuracy
(5) Repeatability
(ii) A 4 d-o-f manipulator of Maker Robot type is shown in the figure given below. Prepare
a D-H parameter table for this configuration. Define the position of end wrist P in
terms of joint lengths and angles: [10 Marks]
Mains Exam
Solution
J4 P4(x4, y4, z 4)
P(x, y, z)
J2 d3
J3
2 (about x-axis) 4 (about x-axis)
1 (about z-axis)
z
y
J1 x
Sol: (i)
(1) Four configurations of Robot
Various types of robot configuration based on work space are
(a) Cartesian Configuration
(b) Spherical or polar Configuration
(c) Cylindrical Configuration
(d) Articulated Configuration
y
x
y
z
z
(c) Cylindrical Arm configuration
(a) Cartesian Configuration


O
y
z
 

(d) Articulated Arm Configuration
(b) Spherical Arm Configuration
Mains Exam
Solution
(2) Work volume: It is a spatial region within which the end of the robot’s wrist can be manipulated.
Work volume is determined by,
 Physical configuration.
 Size of joints and links.
 Number of axes.
 The robot mounted position (over head gantry, wall mounted, floor mounted)
 Limits of arm and joint configurations.
 The addition of an end - effector can move or offset the entire work volume.
(3) Spatial resolution
Spatial Resolution: Smallest increment of motion / movement of the wrist or end effector (tool)
end that can be controlled by the robot. Depends on the position control system, feedback
measurement, and mechanical accuracy.
(Target point)
Robot wrist end Robot wrist end
Normal distribution of
mechanical inaccuracies
One possible
position An Adjacent position An + 1
3 Accuracy
Control Resolution 3
Spatial Resolution
(4) Accuracy:Accuracy: Capability to position the wrist at a target point in the work volume. It is half
of the distance between two adjacent resolution points. It is affected by mechanical inaccuracies.
Manufactures don’t provide the accuracy (hard to control).
Refer to figure shown the following definition can be established :
Control resolution
Accuracy =  3
2
Where,  = Standard deviation of mechanical error
Repeatability = 3   6
Spatial resolution = Control resolution + 6 
Spatial resolution
Accuracy, in terms of spatial resolution =
2
(5) Repeatability: Ability to position back to a point that was previously taught. Repeatability errors
from random variable mechanical accuries in arm, wrist components. Larger robots have less
precise repeatability values.
Repeated
point 'R' Target point 'T'
R
R
ep
Previous position ea Actual point
ta
bi achieved
lit
y
A
Mains Exam
Solution
(ii)
X1 X2 X3 XP
Y1 L2 Y2 Y3 YP
2 4
[1] Z1 [2] Z2 [3] Z3 [4] ZP
d3 L4
L1
Y0
Z0 1 Joint Variable (4 DOF)
1,  2 , d3 ,  4
[0] x0
D  H Parameter Table
Frame ai i di i
0 1 0 90 L1 1  90
1 2 0 2 L2 0
23 0 0 d3 0
34 0 4 L4 0
Ci SiCi S i S i aiCi 

 
 S i CiCi CiSi aiSi 
i1 T
i =  0 S i C i di 


 
 0 0 0 1 
cos  1  90  0 sin  90  1  0
 
 sin  90  1  0  cos  90  1  0
0T = 
1 
 0 1 0 L1 
 
 0 0 0 1
 S1 0 C1 0
 
 C1 0 S1 0
0T
 
1 =  0 1 0 L1 
 
 0 0 0 1
1 0 0 0
 
0 C2 S 2 0
1T
 
2 = 0 S2 C2 L2 
 
0 0 0 0
1 0 0 0
 
0 1 0 0
2T
 
3 = 0 0 1 d3 
 
0 0 0 1
Mains Exam
Solution
1 0 0 0
 
0 C4 S4 0
3T
 
4 = 0 S4 C4 L4 
 
0 0 0 1
0T = 0 T 1 T  2 T2 3 T4
4 1 2
Q.8: (b) (i) Draw the “bathtub curve” and indicate various failure regions. List the major causes
of failure in mechanical components/system. Draw the flowchart for failure modes and
effects analysis (FMEA). [10 Marks]
(ii) Explain the mechanism of metal removal in die-sinking EDM. State the three main
advantages of electron-beam machining (EBM).
[10 Marks]
Sol. (i)
Hazard rate h(t)
Infant Wearout
mortality period
period Constant failure rate
or
useful life period
0 t1 t2
Age or life (hours, cycles, km, etc.)
Fig. Idealized bathtub hazard rate curve

In general, the failure of mechanical parts can occur due to variety of reasons. Some of the most
common failure modes for a mechanical component are mentioned below.
(a) Ductile and Brittle failure
(b) Fatigue that includes high-cycle and low-cycle fatigue, thermal fatigue, surface fatigue, impact
fatigue, corrosion fatigue and fretting fatigue.
(c) Corrosion due to direct chemical attack, galvanic corrosion, crevice and pitting corrosion,
intergranular corrosion, selective leaching, biological corrosion, stress corrosion, corrosion due
to erosion, hydrogen induced corrosion, etc.
(d) Wear [adhesive wear, abrasive wear, corrosive wear, wear due to deformation, imapct fretting
and surface fatigue]
(e) Impact [deformation, wear and fracture due to impact, impact fretting and fatigue]
(f) Fretting [fatigue, wear and corrosion due to fatigue]
(g) Galling and seizure
(h) Creep related failure, combined creep and fatigue
(i) Thermal shock and thermal relaxation
(j) Buckling due to static or dynamic load or due to creep
(k) Localized oxidation
(l) Radiation damage
(m) Bonding failure and / or delamination
(n) Erosion
Mains Exam
Solution
Initiate FMEA of an item
Select a component of the item to analyze
Identify failure modes of the selected component
Select the failure mode to analyze
Identify effect of the failure mode
Determine severity of the final effect
Identify potential causes of that failure mode
Estimate frequency or probability of occurence

for the failure mode during the predetermined
time period
Are there Are there

No No
more failure modes other components for
to analyze? analysis?
Yes Yes
Complete FMEA
Flow chart for FMEA
(ii) Die-Sinker EDM is known by different names such as Ram EDM, sinker EDM, vertical EDM and
plunge EDM. The process is generally used for producing blind cavities. In die-sinker EDM, the electrode
and workpiece are submerged in an insulating liquid such as oil or other dielectric fluids. The electrode
and workpiece are connected to a suitable power supply. An electrical potential is generated between
the tool and the workpiece through the power supply. As the electrode approaches workpiece, the
dielectric break down starts taking place in the fluid. Due to this activity, a plasma channel starts forming
and sparks jump from the electrode to the workpiece leading to material removal from the workpiece.
Electrode
Workpiece
Advantages of EBM:
EBM provides very high drilling rates when small holes with large aspect ratio are to be drilled.
Moreover it can machine almost any material irrespective of their mechanical properties. As it applies
no mechanical cutting force, work holding and fixturing cost is very less. Further for the same reason
fragile and brittle materials can be processed. The heat affected zone in EBM is rather less due to
shorter pulses. EBM can provide holes of any shape by combining beam deflection using electromagnetic
coils and the CNC table with high accuracy.
Mains Exam
Solution
Q.8: (c) A manufacturer of patient medicines is proposed to prepare a production plan for medicines
A and B. There are sufficient ingredients available to make 20000 bottles of medicine A and
40000 bottles of medicine B. However, there are only 45000 bottles into which either of the
medicines can be filled. Further, it takes three hours to prepare enough material to fill 1000
bottles of medicine A and one hour to prepare enough material to fill 1000 bottles of
medicine B, and there are 66 hours available for this operation. The profit is ` 8 per bottle
for medicine A and ` 7 per bottle for medicine B.
(i) Formulate this problem as linear programming problem.
(ii) How does the manufacturer schedule his production in order to maximize profit? Use
graphical method. [20 Marks]
Sol. Let x, be the bottles for medicine A and x2 be the bottles for medicine B.
x1 x2
Than, x1  x2  45000 or  1 ...(i)
45000 45000
3x1 x
 2  66
1000 1000
x1 x2
   1 ...(ii)
22000 66000
x1  20000 and x 2  40000 ....(iii)
x1, x2  0
Maximise Z = 8x1 + 7x2
(0,66000)
(5000, 40000)
(0,45000) (10500, 34500)
E
C
(0,40000) (10500,34500)
B (20000, 6000)
x2 D (22000, 0)
A
(20,000,0) (45000,0)
At Point A
Z = 8 × 20000 = ` 160000
At point C
Z = 7 × 40000 = ` 280000
At point B
Z = 8 × 10500 + 7 × 34500 = ` 325500

At point D
Z = 8 × 20000 + 7 × 6000 = ` 202000

At point E
Z = 8 × 5000 + 7 × 40000 = ` 320000

Hence, the value of Z will be maximum at B (10500, 34500)
Zmax = ` 325500

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Mains Exam

3 × 10 cos30° + 1 × 5 cos30° + T sin15° × 10 cos30° – T cos15° × 10 sin30° = 0

Since thin cylinders, h will be assumed to be constant throughout

Since copper   steel .

 (R)th,copper  ( R)th,steel , this will induce stresses in tube and sleeve.

(h )copper will be compressible and (h )steel will be tensile.

P0D 2.206  120

Classification of Kinematic Pair

NAD = 100 rpm

(ii) A vibrating system has the following constants:

For small vibration, tan   , sin   , cos   1

(1) Damping factor   

d = 1   0.1 2  20  19.899 rad/sec

(3) Logarithmic decrement   

Sol. Axle Shaft

 The shafts are required to transmit same power

Mass of moment of inertia of rotor (I) = mrG2

Gyroscopic couple (C) = IP

= 607.5 × 209.439 × 0.0833

P Active Reactive Bow will move up

(ii) When Ship is Pitching:

Gyroscopic couple (C) = IP

Active Reactive Ship will move

Q.2: (b) A steel cantilever of length 2 m of circular cross-section, 50 mm in diameter, carries

E = 200 GPa = 2  105 N mm 2

L3 L4 L4 L4

Sol. Given: Thick cylinder,

Maximum Permissible stress, P =    30N mm2

P1r22  P1r12  r22P1  r22P2

P1  100 2  8  125 2 100 2  125 2  P1  8  1

 30  5625 = 10000P1  125000  15625P1  125000

12.184  cos  30  6.37 

(iii) Acceleration of fywheel (  )

1454 – 1050.42 = mrG2   where,  is angular acceleration of flywheel

arm C(32) B(20) A(72)

Speed of gear B (NB)

Sol. Rotating mass (mr) = 37 kg

(i) Balance mass required: (mbal)

Horizontal unbalance force (FH) = 1  C  mr2 cos 

Total unbalance force (Fun) = FH 2  FV 2

Sol. Sign Convections

Outer race or cup

(ii) Given:  = 20° full depth involute teeth

ut = 660 N/mm2, BHN = 400, NP = 1500 rpm, Cs = 2, fos = 1.5

 In order to avoid failure of tooth in bending,

Type of Weld Symbol

The primary shear stress in weld is given by

The bending moment Mb is given by

(i) Maximum shear stress theory

16 7.5  7.52  102  7.5  7.52  102 

(i) shear plane angle;

Sol. Given that,

 = tan1  0.618   31.739

F = 1134  sin 6  453.6  cos 6   569.65N

FS = 1134  cos 31.739  453.6  sin31.739

Total Energy = Friction Energy + Shear Energy

Coating Constituent Function

Cellulose Gas former

Data Data Data Variable

As an example, consider a thermocouple-based digital temperature measurement system shown in

Transducer Signal processor Recorder

Sensor for table

Fig. Block diagram representing closed-loop control system

(ii) Open-loop systems and Closed-loop systems