TEST ID: 803

ACE
Engineering Academy
Hyderabad | Delhi |Bhopal | Pune | Bhubaneswar | Bengaluru | Chennai |
Vijayawada | Visakhapatnam | Tirupati

Mechanical Engineering
ESE Conventional Revision TEST – III
Time Allowed: 90 min Maximum Marks: 100

INSTRUCTIONS
Please read each of the following instructions carefully before
attempting questions:
Candidates should attempt THREE questions in all.
Question No.1 is compulsory. Out of the remaining THREE questions
attempt any TWO.

The number of marks carried by a part of a question is indicated against

it.

Answers must be written in ENGLISH only.

Unless otherwise mentioned, symbols and notations have their usual

standard meanings.

Assume suitable data, if necessary and indicate the same clearly.

Neat sketches may be drawn, wherever required.

All parts and sub-parts of a question are to be attempted together in the

answer book.
Any pages left blank in the answer book must be clearly struck out.

[contd.]

1
 ESE – Offline Test

01(a). Make a program in APT language for milling the

contour shown in figure in a single parts. Assume
suitable Data. (20M)
50
C1
R25

100 50

20

20

01(b). In a slab milling operation with straight teeth cutter,

the cutter has 15 teeth with 10o rake angle and rotates
at 200 rpm. The diameter of cutter is 80mm and table
feed is 75 mm/min, The depth of cut is 5mm. The
width of MS slab is 50mm and ultimate shear stress of
work material is 420 N/mm2. Assuming the
coefficient of friction between chip and cutter to be
0.7 and using lee and Shaffer relation, plot variation
of resultant torque with cutter rotation and estimate
avg. power consumption. (17M)

2
 ME – RT Conv - 3

01(c). Explain the term:

(i) Coring (3 M)

02(a). A hole is to be drilled in a high strength copper alloy

work piece with a 10mm bit at a feed rate of
0.2mm/rev, the spindle speed is 500rpm. Estimate the
material removal rate and the torque required for this
operation. Take specific energy values of the work
material as 1.9W.s/mm3
(10M)

02(b). Calculate the material removal rate and electrode feed

rate in the ECM of an iron surface that is 25 mm x 25
mm in cross section, using NaCl in water as
electrolyte. The gap between the tool and the work
piece is 0.25 mm. The supply voltage is 12 V.D.C.
The specific resistance of electrolyte is 3  cm. Take
iron valency = 2; Atomic weight = 55.85, Density =
7860 kg/m3 . (10 M)

3 [contd.]
 ESE – Offline Test

02(c). Discuss 3 common defects observed in sand castings.

Indicate their causes and remedies. (6M)

02(d). Draw the Goodman straight line and the Soderberg

straight line for designing under fatigue loads.
(4M)

03(a). Calculate mass and volume fraction of the phases

present in an alloy with 45% tin at 100oC . At this
temperature 10% tin can be dissolved in lead and 2%
lead is dissolved in tin. At this temperature density of
lead and tin are 10.96 g/cm3 and 13.28 g/cm3
(10 M)

03(b). Explain the various methods of powder production,

and the types of power produced ? (10 M)

4
 ME – RT Conv - 3

03(c). Design General type GO and NO GO gauges for

components having 75 H8f9 fit. The basic size falls in
the diameter range of 50–80mm. The fundamental
deviation for ‘f’ shaft = –5.5D0.4 microns. The
multipliers for 8 and 9 grades are 25 and 40. Take
wear allowance as 10% of gauge tolerance.
(10 M)

04(a). Explain the difference between tolerance and

allowance. Write in short about optical flat. Two
fringe patterns are supplied for two completely
different surfaces using optical flat, name the types of
surfaces, and draw if required. Discuss with fig.
principle of working of a pneumatic gauge. Fringe
pattern for two completely different types of surfaces.
(10M)

04(b). Explain Hume – Rothery Rule?

(5 M)

5 [contd.]
 ESE – Offline Test

04(c). Explain the effects of Heat and H2 bubble generation

in the electrolyte used for ECM process ?
(5 M)

04(d). Explain the functions of electrolyte in ECM ? List the

electrolytes used for various types of alloys ?
(5 M)

04(e). Explain the various defects in extrusion process.

(5 M)

6
 ME – RT Conv - 3

SPACE FOR ROUGH WORK

7 [contd.]
 ESE – Offline Test

SPACE FOR ROUGH WORK