Detailed Solutions

ESE-2018 Mechanical Engineering

Mains Test Series Test No : 11
Section A
Q.1 (a) Solution:
Given: W rod = 4.4 N, LAB = 1.2 m, Wdisk = 18 N, rAD = 0.34 m, k = 0.7 N/m, x = 0.31 m,
yC = 1.4 m
C

yC k
B A
D
LAB LAB
2 2
rAD

By energy conservation:
2
1 2 1 ⎡⎛ 1 2 ⎞ ⎤ 2 ⎡ 1 2 ⎛L ⎞ ⎤ω
2
Force × displacement = kx + ⎢⎜ mr ⎟ ⎥ ω + ⎢ mL + m ⎜ + r ⎟ ⎥
2 2 ⎣⎝ 2 ⎠⎦ ⎣⎢ 12 ⎝2 ⎠ ⎦⎥ 2

1 2 1
⎛ 18 × 0.34 2 ⎞ 2
4.4 × (0.6 + 0.34) = × 0.7 × (0.6 + 0.34) + × ⎜ ⎟ω
2 2 ⎜⎝ 2 × 9.81 ⎟⎠
⎡ 4.4 × 1.2 2 4.4 × (0.6 + 0.34)2 ⎤ ω2
+⎢ + ⎥×
⎢⎣ 12 × 9.81 9.81 ⎥⎦ 2

1 2
4.136 – 0.30926 = ω [0.106055 + 0.053823 + 0.396314 ]
2
 Test No : 11 MECHANICAL ENGINEERING | 11

2 × (4.136 − 0.30926)
ω2 = = 13.7605
0.556192
ω = 3.7095 rad/s

Q.1 (b) Solution:

Given: D = 300 mm, p = 1.8 N/mm2, n = 8, σyt = 320 MPa, σe = 250 MPa, P1 = 1.5 P2, FOS
= 2, k = 0.8.
We know that steam load acting on the cylinder head,

π 2 π
P2 = (1) P = (300)2 × 1.8
4 4
= 127234.50 N
Initial pre load, P1 = 1.5P2 = 1.5 × 127234.50 = 190851.75 N
Resultant load (maximum load) on the cylinder head,
Pmax = P1 + kP2
= 190851.75 + 0.8 × 127234.50
= 292639.35 N
Maximum load on each bolt,
292639.35
Pmax = = 36579.918 N
8
Minimum load on each bolt,
190851.75
Pmin = = 23856.468 N
8
Pmax + Pmin 36579.918 + 23856.468
Mean load on bolt, Pm = =
2 2
= 30218.193 N

Pmax − Pmin 36579.918 − 23856.468

Variable load on the bolt, Pv = =
2 2
= 6361.725 N
Let dc = Core diameter of the bolt in mm
π
∴ Cross-section of bolt, As = ( dc )2
4
Pm 30218.193 38474.9983
Mean stress, σm = = =
As π dc 2
( dc )2
4
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12 | ESE 2018 : MAINS TEST SERIES

Pv 6361.725 8099.99
Variable stress, σv = = =
As π dc 2
( dc )2
4
According to Soderberg’s theory,
σ v σm 1
+
σ e σ yt = FOS
8099.99 38474.9983 1
+ =
dc2 × 250 dc2 × 320 FOS
152.634 1
=
dc2 3
dc = 21.39 mm = 22 mm

Q.1 (c) Solution:

Given: b = 1.65 m, R = 30 m, dw = 0.4 m

b
R = 30 m

Angular velocity of vehicle w.r.t center of road curvature;

1000
45 ×
3600 ⇒ 5 rad/ s
ω =
30 12
When outer wheel does not slip.
⎛ b⎞
ω × ⎜R + ⎟ = ω × R
⎝ 2⎠ 0 w

5 ⎛ 1.65 ⎞
× ⎜ 30 + ⎟ = ω0 × 0.2
12 ⎝ 2 ⎠
ω 0 = 64.22 rad/s
30
N0 = 64.22 × = 613.3 rpm
π
when inner wheel does not slip,

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 Test No : 11 MECHANICAL ENGINEERING | 13

⎛ b⎞
ω × ⎜R − ⎟ = ωi × Rw
⎝ 2⎠
5 ⎛ 1.65 ⎞
× ⎜ 30 − ⎟ = ωi × 0.2
12 ⎝ 2 ⎠
ωi = 60.78 rad/s

ω0 + ωi 64.22 + 60.78
Speed of ring gear ωB = ⇒ = 62.5 rad/s
2 2
30
Ni = 60.78 × = 580.4 rpm
π
NB = 596.8 rpm

Q.1 (d) Solution:

(Fc)x = 360 kgf
(Fc)y = 400 kgf 74.756 kgf
θ
Magnitude of the force (P):
Taking moment about the hinge B.
400 × 20 cos30° – 360 × 20 sin30° = (P × sin50°) × 15
P = 289.644 kgf
349.70 kgf
Magnitude of the reaction at B:
(RB)x = Pcos10° – 360
= –74.756 kgf or 74.756 kgf (←)
(RB)y = 400 – Psin10°
(RB)y = 349.70 kgf (↓)
Magnitude of the reaction at B,

RB = ( RB )2x + ( RB )2y = 74.756 2 + 349.70 2

= 357.60 kgf
349.70
tanθ = = 77.93° or 257.93°
74.756
Q.1 (e) Solution:
Controllability: A system is said to be completely controllable, if there exists a control
law (a signal, say u(t)) which could drive the state (all the state variables) from an initial
value to a final value, within a finite interval of time. If all the state variables cannot be
controlled(at least one variable can be changed), then the system is NOT completely
controllable. It may be termed as partially controllable. Actually controlling a system,
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14 | ESE 2018 : MAINS TEST SERIES

in a way, means to modify/change/manipulate some parameters/state variables of the

system, in a proper fashion, so as to achieve the desired response. So, if you can modify/
change/manipulate the state variables, then obviously the system can be controlled.
Thus, the name as controllable system.
Observability: To control a system, it is required to monitor the controlled variable.
Sensors are used to monitor/measure the controlled variable. But, in some cases, it is
not possible to measure the variables by using sensors, as those parameters may not be
directly accessible for measurement or sensing. In such cases, the output, is observed,
for a finite duration of time, so as to estimate the inaccessible variables/parameters/
state variables . A system, whose state(all state variables) can be estimated, by observing
the output of the system, for a finite duration of time, is called completely observable. If
a system is not completely observable, then the unobservable variables/parameters,
since not be sensed, cannot be monitored.
In nutshell, controllability is related to the control input, whereas observability is related
to the output.

Q.2 (a) Solution:

Case I:
W

2d dx C
A B

L k=L

Extend the upper and lower faces of the cantilever to meet at C.

By similar triangle,

2d d
=
AC BC
2BC = AC
2k = k + L
k = L
At any section x from C, (x > L)

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 Test No : 11 MECHANICAL ENGINEERING | 15

⎛x ⎞
d x = ⎜⎝ × d⎟⎠
L

π ⎛ x 4d 4 ⎞
∴ Ix = ⎜ ⎟
64 ⎝ L4 ⎠

d2 y
EI = Mx
dx 2
d2y W ( x − L) 64 ⎛ x − L⎞
E = − = − 4 WL4 ⎜ 4 ⎟
dx 2 π ⎛ x 4d 4 ⎞ πd ⎝ x ⎠
64 ⎜⎝ L4 ⎟⎠

⎧⎪ 64 WL4 ⎫⎪
= –Q(x–3 – Lx–4) ⎨where, = Q ⎬
⎩⎪ πd 4 ⎭⎪
dy ⎡ x −2 Lx −3 ⎤
On interating, E = −Q ⎢ − ⎥ + C1
dx ⎢⎣ −2 −3 ⎥⎦

dy
We know that, at, x = 2L, =0
dx
⎡ (2L)−2 L ⎤
0 = −Q ⎢ − × (2L)−3 ⎥ + C1
⎣⎢ −2 −3 ⎦⎥
⎡ 1 1 ⎤ 2Q Q
C1 = Q ⎢ − ⎥ = − = −
⎣ 24L2 8L2 ⎦ 24L2 12L2

⎡ x −1 Lx −2 ⎤ Qx
Again integrating, Ey = −Q ⎢ − ⎥− + C2
⎢⎣ 2 6 ⎥⎦ 12L2

We know that,
⎡ 1 L ⎤ Q × 2L
At x = 2L, y = 0, 0 = −Q ⎢ − ⎥− + C2
⎣ 4L 6 × 4L2 ⎦ 12L2
⎡ 5 ⎤ Q
Q⎢ + = C2
⎣ 24L ⎥⎦ 6L
9Q 3Q
C2 = =
24L 8L

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16 | ESE 2018 : MAINS TEST SERIES

⎡ 1 L ⎤ Qx 3Q
Ey = −Q ⎢ −
2 ⎥ −
2
+
⎣ 2 x 6x ⎦ 12L 8L
For the free end, x = L,
Q⎡ ⎛ 1 L ⎞ L 3⎤
Hence, yB = E ⎢ − ⎜ 2 L − 2 ⎟− 2
+ ⎥
8L ⎦
⎣ ⎝ 6L ⎠ 12 L
Q⎡ ⎛ 2 ⎞ 1 3⎤
= ⎢ −⎜ ⎟ − + ⎥
E ⎣ ⎝ 6L ⎠ 12L 8L ⎦

Q ⎡ −8 − 2 + 9 ⎤ Q 64 WL4
= =− =− 4
E ⎢⎣ 24L ⎥⎦ 24LE πd × 24EL
64 ⎛ WL3 ⎞
= ⎜ ⎟ (↓ )
24 π ⎝ Ed 4 ⎠

Case II: Deflection at free end for a cantilever beam of uniform diameter 2d.
WL3 WL3 64WL3
(yB)2d = = = (↓ )
3EI π 4 48 πEd 4
3E × × (2 d )
64
⎡ (y ) − ( y B )2 d ⎤
% Error = ⎢ B Actual ⎥ × 100%
⎣ ( y B )Actual ⎦
⎡ ⎛ 64 WL3 ⎞ ⎛ 64 WL3 ⎞ ⎤
⎢⎜ −
4⎟ ⎜ 4⎟
⎥
⎢ ⎝ 24 πEd ⎠ ⎝ 48πEd ⎠ ⎥
= ⎢ ⎥ × 100%
⎢ ⎛ 64 WL3 ⎞ ⎥
⎢ ⎜ 4⎟ ⎥
⎣ ⎝ 24πEd ⎠ ⎦
⎛ 1 − 1 / 2⎞
= ⎜
⎝ ⎟⎠ × 100%
1
% Error = 50%

Q.2 (b) Solution:

The gears D and G are not part of the epicyclic gear train, so we consider the rest of the
train and calculate the speed of D from that of E, and the speed of G from that of F. The
number of teeth on the annular wheel C is
NC = NH + NK + NL

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 Test No : 11 MECHANICAL ENGINEERING | 17

Rotations of
Arm Gears*
Condition (Gear F)
E and H K and L C
Gears locked y y y y

Arm fixed 0 x – 40 x – 40 × 30 x
20 20 90

Resultant y x+ y y – 40 x y – 40 × 30 x
20 20 90

Since rC = rH + rK + rL, and assuming the pitch to be same for all the gears. Thus, NC =
40 + 20 + 30 = 90. The epicyclic train, consisting of the arm (pin) and gears E, F, H, K, L
and C is solved by the tabular method as shown in above table.
It is given that nC = 0 and nD = 270 rpm. So,
40 40
nE = nD = × 270 = 360 rpm(CCW)
30 30
(when viewed from the top),
2
nE = x + y = 360, nC = y −
x = 0.
3
Solving these equations, we get x = 216 rpm, y = 144 rpm. Therefore,
nF = y = 144 rpm (CCW) (when viewed from the top),
NF 50
nG = nF = × 144 = 90 rpm(CCW)
NG 80
(when viewed from the right).
Thus, the output shaft rotates at 90 rpm in a direction opposite to that of the input shaft.

Q.2 (c) Solution:

Assume the diameter of the journal (d) = 70 mm
Length of the journal (l) = 1.2d
l = 1.2 × 70 = 84 mm
W 220 00
Bearing pressure, p = = = 3.74 N/mm2
l×d 70 × 84
∴ p > 3.5 so choosing next diameter
1. Assume the diameter of the journal (d) = 100 mm
Length of the journal (l) = 1.2d
l = 1.2 × 100 = 120 mm
W 22000
2. Bearing pressure, p = = = 1.83 N/mm2
l × d 120 × 100

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18 | ESE 2018 : MAINS TEST SERIES

Since maximum bearing pressure for the pump is 3.50 N/mm2. therefore the above
value of p is safe and hence dimensions of l and d are safe.
Z.N 0.045 × 850
3. = = 10.928
p 3.5
From table, we find the value of
Z.N
p = 12.8
that the minimum value of the bearing modulus at which the oil film will break is given
by
Z.N
3k = p
1 ⎛ ZN ⎞ 1
k = 3 ⎜ p ⎟ = 3 × 12.8 = 4.26
⎝ ⎠

⎛ ZN ⎞
Since the calculated value of bearing characteristics number ⎜ = 10.928⎟ is more
⎝ p ⎠

than 4.26. Therefore the bearing will operate under hydrodynamic conditions.
4. From table, we find that for pumps, the clearance ratio (c/d)
= 0.0010
33 ⎛ ZN ⎞ d
5. Coefficient of friction, μ = ⎜ ⎟ × + 0.002
108 ⎝ p ⎠ c
33 1
= 8
× 10.928 × + 0.002 = 0.0056
10 0.001
⎛ π × 0.1 × 850 ⎞
Heat generated, Qg = μWv = 0.0056 × 22000 × ⎜⎝ ⎟⎠
60
= 548.3126 W
Heat dissipated, Qd = CA(tb – ta) [A = l × d]
1 1
where tb – ta = (t0 − t a ) = (55 − 15.5) = 19.75° C
2 2
= 1332 × 0.12 × 0.10 × 19.75
= 315.684 W
Since Qg > Qd
Excess heat = Qg > Qd = 548.3126 – 315.684
ΔQ = 232.6286 W
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 Test No : 11 MECHANICAL ENGINEERING | 19
Mass of lubricating oil required for artificial cooling.
Qt = ΔQ
m × Soil × Δt = ΔQ
 × 2000 × 15 = 232.6286
m
m = 7.75429 × 10–3 kg/s
= 0.465 kg/min
= 27.9154 kg/hr

Q.3 (a) Solution:

For diagram:
For CB section, measuring x from C,
T x = (4 – 8) + 4(4 – x)
= 12 – 4x (Linear variation)
Torque is zero at, T x = 0, 0 = 12 – 4x
x = 3m
At, x = 0 m, TC = 12 kN-m ( )
At, x = 4 m, TB = 12 – 4 × 4
= –4 kN-m or 4 kN-m [On the left side of B]
Now, (TB)x=4 m on right side of B = –4 + 8 = 4 kN-m ( ) [Constant]
θ : Diagram
Calculating from the fixed end,
TL
θ =
GJ
x x
Tx × dx 10.186
For segment, CB, ∫
θx = G × π d 4
=
Gd 4 ∫
(12 − 4 x )dx
0 0
32
10.186
= (12x − 2x2 ) [Parabolic variation]
4
Gd
At C, x = 0,
Hence, θC = 0
10.186
At B, x = 4 m, θB = 4
(12 × 4 − 2 × 4 2 )
Gd
162.976
=
Gd 4
θ is maximum, where T is zero i.e. x = 3 m

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20 | ESE 2018 : MAINS TEST SERIES

10.186 183.348
(θ)x=3m = 4
(12 × 3 − 2 × 32 ) =
Gd Gd 4
For segment AB,
[Measuring x from B]
x′ x′
10.186 162.976 10.186
θx = θ B +
4 ∫
Tx dx′ =
Gd 4
+
Gd 4 0
∫ 4.dx′
0 Gd
162.976 ⎛ 40.744 ⎞
= +⎜ × x′ [Linear variation]
Gd 4 ⎝ Gd 4 ⎟⎠
162.976
Now at B, x′ = 0, θB =
Gd 4
162.976 40.744 × 2
Now at A, x′ = 2 m, θA = 4
+
Gd Gd 4
244.464
θA =
Gd 4
4 kN-m
8 kN-m
4 kN-m/m
B
C A

8 kN-m 4 kN-m
4m 2m
12 kN-m

+ 4 kN-m 4 kN-m
1m +
– 2m
3m
4 kN-m

244.464
183.348 Gd4
(θ) = 162.976
Gd4
Gd4

3m

4m 2m

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 Test No : 11 MECHANICAL ENGINEERING | 21
Q.3 (b) Solution:
Equation of motion can be written as
mx + cx + kx = 0
−ξω t
and solution is given by, x = e n [ A cos ωdt + B sin ωdt ] ... (i)
k 3000
ωn = = = 12.25 rad/ s
m 20
C 120
ξ = 2mω = 2 × 20 × 12.25 = 0.245
n

Damped frequency, ωd = ω n 1 − ξ 2 = 12.25 1 − 0.2452

= 11.88 rad/s Answer

Substituting the values of ωn, ωd and ξ in equation (i), we get
x = e−0.245×12.25t [ A cos(11.88t ) + B sin(11.88t )]

= e −3t [ A cos(11.88t ) + B sin(11.88t )] ... (ii)

at t = 0, x = 0;
0 = e(0) {Acos0 + Bsin0}
⇒ A = 0
x = e–3t.Bsin(11.88t)
⎛ dx ⎞ −3t −3t
x = ⎜ ⎟ = B ⎣⎡ e cos(11.88t ) × 11.88 − 3 e sin(11.88t )⎦⎤
⎝ dt ⎠
at t = 0, x = 0.2 m/s 0.2 = B[e0 cos(0) × 11.88 – 3e0 sin0]
B = 0.0168
Displacement equations;
x = 0.0168 e–3t sin(11.88t) ⇒ f(t) only
Velocity equations, x = 0.0168 e–3t [11.88 cos(11.88t) – 3sin(11.88t)]
t = 0.5 second
x = 0.0168 e–3 × 0.5 sin(11.88 × 0.5)
x at 0.5 s = –1.261 × 10–3 m or 1.261 mm above mean position
x at 0.5 s = 0.0168 e–3 × 0.5 [11.88 cos(11.88 × 0.5) – 3 sin(11.88 × 0.5)]
= 0.046 m/s (in downward direction)

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22 | ESE 2018 : MAINS TEST SERIES

Q.3 (c) Solution:

Syt = 275 N/mm2, FOS = 4.5, Sus = 375 N/mm2
diameter of bar to be sheared = 6.50 mm
for pins, p = 12 N/mm2
l/d = 1.45
Step 1: Calculation of forces maximum force Ps required to shear the bar is
Ps = (Area of shear) × (Ultimate shear strength)
π 2 π
= D × Sus = (6.5)2 × 375
4 4
= 12443.652 N
FBD of forces acting on various parts of the shearing machine.

RAY P1
A P1 B
RAX
B
PS
S C P1

PS RD P

D
PS P1

Moment about A,
P1 × 450 + Ps × 150 × cos60° = Ps × cos30° × 200
P1 × 450 = Ps(cos30° × 200 – 150 × cos60°)
= 12443.652 × 98.2050
= 2715.62 N
RAy + P1 = Ps × cos30°
RAy = 12443.652 × cos30° – 2715.62
= 8060.898 N
Take moment about point D
P × 880 = P1 × 80
2715.62 × 80
P = = 246.874 N
880
R D = P1 – P = 2715.62 – 246.874
= 2468.746 N

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 Test No : 11 MECHANICAL ENGINEERING | 23
Forces acting on pins at B, C, D are
PB = 2715.62 N
PC = 2715.62 N
PD = 2468.746 N
We will design the pin for maximum force of 2715.62 N
Considering bearing pressure on the pin,
PB = PC = R = P(d1 × l1)
2715.62 = 12(d1 × 1.45 d1)
d1 = 12.49 ≈ 13 mm Answer.
l1 = 13 × 1.45 = 18.85 ≈ 20 mm Answer.
The pin is subjected to double shear stress.
R 2715.62
τ = = = 10.23 N/mm2
⎡π 2⎤ ⎡π ⎤
2 ⎢ d1 ⎥ 2 ⎢ × 132 ⎥
⎣4 ⎦ ⎣4 ⎦
Ssy Syt 275
τpermissible = = = = 30.55 N/mm2
FOS 2 × FOS 2 × 4.5
τ < τpermissible
So, design is safe.

Q.4 (a) Solution:

π π
A1 = × d12 = × 182 = 254.47 mm 2
4 4
π π
A2 = × d22 = × 152 = 176.714 mm 2
4 4
Assuming, stress developed in upper portion is σ1 and stress in lower portion is σ2,
then at common point,
σ1A1 = σ2A2
176.714
σ1 = σ2 × = 0.69444 σ 2
254.47
π 2 π
Volume of upper section, V1 = d1 l1 = (18)2 × 100
4 4
= 25446.9 mm3
π 2 π
Volume of lower section, V2 = d2 l2 = (15)2 × 80
4 4

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24 | ESE 2018 : MAINS TEST SERIES

= 14137.167 mm3
By energy conservation,
Change in PE = Change in strain energy
σ12 σ2
W(h + δl1 + δl2) = × V1 + 2 × V2
2E 2E
⎛ σ l σ l ⎞ (0.69444σ2 )2 × V1 σ22
25 ⎜ 40 + 1 1 + 2 2 ⎟ = + × V2
⎝ E E ⎠ 2E 2E
⎛ (0.69444 × 100σ 2 ) + σ 2 × 80 ⎞ σ 22
25 ⎜ 40 +
⎝ E
⎟⎠ =
2E
[12271.689 + 14137.167 ]
⎛ 40E + 149.444σ 2 ⎞ σ 22
50 ⎜
⎝ E
⎟⎠ =
E
[ 26408.856]
26408.856σ22 – 7472.2σ2 – 2000 × 210 × 103 = 0
On solving, σ 2 = 126.2516; – 125.968
Maximum stress developed, σ2 = 126.2516 MPa
Q.4 (b) Solution:
FBD of cylinder with center A,

A
A
D E
W
B θ θ C W
Rd Re
kr

FBD of semicylinder with center B,

Rd
D
Nb
θ
μNb

W/2
For equilibrium of cylinder, A
By symmetry, R d = Re
Now, (Rd + Re)sinθ = W
2Rdsinθ = W
W
Rd = ... (i)
2 sin θ
Now, for cylinder with center, B

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 Test No : 11 MECHANICAL ENGINEERING | 25
Rdcosθ – μNb = 0
W
× cos θ = μNb
2 sin θ
W cos θ W
Nb = = cot θ ... (ii)
2 × 0.4 sin θ 0.8
W W W
Now, Nb = + Rd sin θ = + × sin θ = W ... (iii)
2 2 2 sin θ
Now, putting the value of Nb is equation (ii)
W
W = cot θ
0.8
tanθ = 1.25
2
2 ⎛ kr ⎞
(2 r ) − ⎜ ⎟
⎝ 2⎠
Now, tanθ = = 1.25
kr
2

2k 2r 2 1.25
4r − = kr
4 2
Squaring on both side
2
2k 2r 2 ⎛ 1.25 ⎞ 2 2
4r − = ⎜ k r
4 ⎝ 2 ⎟⎠

k 2r 2
4r2 = [1 + 1.5625]
4
6.2439r2 = k2r2
kr = 2.49878r

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26 | ESE 2018 : MAINS TEST SERIES

Q.4 (c) Solution:

Outer cranks
Inner cranks

1
1 RP 2 3 4

2 4
0.9 m 1.2 m 0.9 m
3

3m
(a) Crank position (b) Crank arrangement
2 πN 2 × 3.14 × 105
ω = = = 10.996 rad/s
60 60
Radius or crank, r = 0.4 m
The primary force are always balanced as cranks are arranged at an angular
displacement of 90° to each other. The position of cranks are shown in figure XIV.
We have to find out primary unbalanced couples. The possible firing orders are :
1234, 1423, 1324, 1342, 1432. The disturbing force acts along the axis of the cylinder
and equal to = mω2rcosθ
let k = mw2r = 850 × (10.996)2 × 0.4 = 41107 N
4
Total disturbing force = ∑ k cos(θ + αi )
i =1
where αi = angle between the reference crank and the crank considered.
Plane of Mass, mr Arm length
k = mω2r Couple = kl
cylinder kg (kg.m) l(m)

1 850 340 41107 0 0

2 850 340 41107 0.9 0.9 k

3 850 340 41107 2.1 2.1 k

4 850 340 41107 3 3k

Let us investigate resultant primary couple for each and every possible firing order
First firing order (1 2 3 4)
1

2 4 0.9 k 3k

2.1 k
3
Crank Positions Primary Couple Polygon

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Resultant primary couple : [(3 − 0.9)k ]2 + (2.1k )2 = 2.97 k

Second firing order (1 2 4 3)

1

2 3 0.9 k 2.1 k

3k
4

Crank Positions Primary Couple

Polygon

Mc = ( 2.1k − 0.9 k )2 + (3k )2 = 3.231 k

Third firing order (1 4 2 3)

4 3 3k 2.1 k

0.9 k
2
Crank Positions Primary Couple
Polygon

MC = ( 2.1k − 3k )2 + (0.9 k )2 = 1.273 k

Fourth firing order (1 3 2 4)

1

3 4 2.1 k 3k

0.9 k
2
Crank Positions Primary Couple Polygon

MC = ( 3k − 2.1k )2 + (0.9 k )2 = 1.273 k

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Fifth firing order ( 1 3 4 2)

1

3 2 2.1 k 0.9 k

3k
4

Crank Positions Primary Couple Polygon

MC = (2.1k − 0.9 k )2 + (3 k )2
MC = 3.231 k
Sixth firing order 1432
1

4 2 3k 0.9 k

2.1 k
3
Crank Positions Primary Couple Polygon

Mc = (3 k − 0.9 k )2 + (2.1k )2 = 2.97 k

Least value of primary couple = 1.273 k = 1.273 × 41107 = 52329 N.m
Best firing order is 1423 and 1324.

Section B
Q.5 (a) Solution:
4x1 + 5x2 ≥ 50 ... (i)
3x1 + 2x2 ≥ 30 ... (ii)
2x1 + 5x2 ≥ 40 ... (iii)
x1 , x2 ≥ 0
Minimize, Z = 7x1 + 12x2

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 Test No : 11 MECHANICAL ENGINEERING | 29
x2

15

10
8

4x1 + 5x2 ≥ 50

12.5

10 20 x1
3x1 + 2x2 ≥ 30
2x1 + 5x 2 ≥ 40
3x1 + 2x2 = 30
2x1 + 5x2 = 40
On solving (ii) and (iii)rd all inequality satisfied
nd

x 1 = 6.3636
x 2 = 5.4545
So, minimum cost is `110.
because Z(0, 15) = 7 × 0 + 12 × 15 = 180
Z(20, 0) = 20 × 7 + 12 × 0 = 140
Z(6.3636, 5.4545) = 7 × 6.3636 + 12 × 5.4545 = 109.999  110

Q.5 (b) Solution:

Transverse bending test is most frequently employed for determining stress train
behavior of brittle ceramics. In this method a rod specimen having either a circular or
rectangular cross-section is bent until fracture using a three or four point loading
technique. At the point of loading, the top surface of the specimen is placed in a state of
compression, while the bottom surface is in tension. Stress is computed from the
specimen thickness, the bending moment and the moment of inertia of the cross-section,
for rectangular and circular cross-sections.
F

b
d
Rectangular
d
Circular

3 point testing method

The stress strain behavior of brittle ceramics is not usually measured by a tensile test for
three reasons:

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1. It is difficult to prepare and test specimens having the required geometry.

2. It is difficult to grip brittle materials without fracturing them.
3. Ceramics fail after only about 0.1% strain, which necessitates that tensile specimens
be perfectly aligned to avoid the presence of bending stresses which are not easily
calculated.

Q.5 (c) Solution:

t0 + tm + tp
Activity t0 tm tp te = 6 Variance
1-2 12 15 24 16 4
1-3 6 8 10 8 4/9
2-3 10 12 14 12 4/9
2-4 6 6 6 6 0

3-4 7 9 11 9 4/9

4-5 13 17 27 18 49/9

16 16

2
16 6

18
1 4 5

0 0 37 37 55 55
8 9
3

28 28

Critical path = 1 – 2 – 3 – 4 – 5
Critical path duration = 55 days
4 4 49
Variance along critical path, σ2 = 4 + + +
9 9 9

Standard deviation, σ = 10.333 = 3.2145 days

Probability such that project cannot be complete in given time is 5% means probability
of project completion is 95%.
Time required, Ts = TE + Zσ
= 55 + 1.65 × 3.2145
Minimum time required, T = 60.3 days

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Q.5 (d) Solution:
Energy type Mechanics of material Energy source Process
removal

Mechanical Plastic shear Mechanical motion Conventional machining

of tool/job
Mechanical/fluid motion Abrasive jet machining (AJM)
Erosion
Ultrasonic machining (USM)

Electrochemical Ion displacement Electric current Electrochemical machining (ECM)

Mechanical and Plastic shear and Electric current and Electrochemical grinding (ECG)
Electrochemical ion displacement mechanical motion

Chemical Corrosive reaction Corrosive agent Chemical machining (CHM)

Electric spark Electric discharge machining (EDM)

High speed electrons Electron beam machining (EBM)

Thermal Fusion and vaporization
Powerful radiation Laser beam machining (LBM)
Ionized substance Ion beam machining (IBM)
Plasma arc machining (PAM)

Q.5 (e) Solution:

The material-removal rate (MRR) is determined as
MRR = dwv = (0.05)(2.5)(1500) = 187.5 mm3/min
The power consumed is given by
Power = (u)(MRR),
where u is the specific energy, as obtained. For low-carbon steel, it is estimated to
be 40 J/mm3. Thus

Ws ⎛ 1min ⎞ mm 3
Power = 40 ⎜ ⎟ 187.5 = 125 J/s
mm 3 ⎝ 60 s ⎠ min

By noting that 1 W = 1 Nm/s = 60 Nm/min,

Power = (1.25 × 102)(60) = 7500 Nm/min
Since power is defined as
Power = Tω,
where the torque T = Fc (D/2) and ω is the rotational speed of the wheel in radians per
minute (ω = 2πN). It follows that
⎛ 250 ⎞ ⎛ 1m ⎞
7500 = (Fc ) ⎜⎝ 2 ⎟⎠ ( 2 π )( 4000 ) ⎜ 1000 mm ⎟
⎝ ⎠

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and therefore, Fc = 2.4 N

The thrust force, Ft, can be calculated directly, however, it is also can be estimated by
noting from experimental data in the technical literature that it is about 30% higher than
the cutting force, Fc, consequently,
Ft = (1.3)(2.4) = 3.12 N

Q.6 (a) Solution:

Rolling: The sources of defects in a typical rolling operation are mainly surface
irregularities, nonmetallic inclusions, and internal blow holes in the stock.
The first source may lead to a trapping of scales which remain inside as laps.
The second source produces, especially during the hot rolling of a thick slab, crocodile
cracks, separating the product into two halves. The third source results in an elongation
of the blow holes and the product becomes weaker. During the rolling of a complex
shape, nonuniform deformation (as some portions elongate due to direct compression,
whereas the adjoining sections, free from direct compression, elongate due to the
dragging action of the portions under direct compression) gives rise to the development
of secondary tensile stresses, resulting in internal cracks. If the deformation takes place
mostly at the surface, the product may be left with residual stresses. The foregoing
defects can be minimized by a careful inspection of the billet and by keeping the roll
smooth and clean. To avoid the internal cracks, it is necessary to properly design the
roll pass.
Forging: The faults in forged products originate from various sources, e.g., defects in
the stock, improper heating, and poor die design. The cracks around the corners and at
right angles to the forged surface, known as cold shuts, arise due to the misplacement of
the metal in the die. In closed die forging, sometimes unfilled sections result mainly
due to less amount of metal, improper heating and misplacement of the metal. If the
scales are not removed from the die surface, these are transferred to the subsequent
forging, which, when removed, leave scale pits. If the two halves of the die are misaligned,
mismatched forging may result. When the lubrication is insufficient, too much barreling
(bulging of the free surface due to the pressure from the internal flowing material during
open die forging) along with cracks on the free barreled surface may develop.
Wire drawing : The typical surface defects in rod and wire drawing are due to a ploughing
by hard particles and local breakdown of the lubricating film. The other kinds of defects
include the formation of a bulge, ahead of the die, with low reduction and high die
angle, and the development of a centre burst with too large a deformation gradient
along the cross-section. Below figure (a) shows a case of drawing where the half die
angle α is large and the reduction ratio is low, i.e., h/L is large. In such a situation, the
deformation is localized near the surface and the relatively undeformed central portion
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 Test No : 11 MECHANICAL ENGINEERING | 33
is dragged forward by the upper layer. This causes the development of secondary tensile
stresses, resulting in the centre-burst defect. Figure (b) shows the centre-burst defect
during extrusion. When h/L is less than 2, the danger is less.
α
df L

di L h h
α

(a) In drawing (b) In extrusion

Development of centre-burst defect

Drawing operations: As already noted, many types of deformations are involved in the
drawing operations on sheet metals. Following figures illustrates the various types of
common deep drawing defects. An insufficient blank holder pressure causes

Flange wrinkles Wall wrinkles Fractured rim and bottom

Corner fracture Directional earing Miss strike

wrinkles to develop on the flange, which may also extend to the wall of the cup Further,
too much of a blank holder pressure and friction may cause a thinning of the walls and a
fracture at the flange, bottom, and the corners (if any). While drawing a rolled stock, ears
or lobes tend to occur because of the anisotropy induced by the rolling operation. Moreover,
due to the misplacement of the stock unsymmetrical flanges may result. This type of
defect is commonly referred to as a miss strike. The effect of a large grain size is to produce
a dull surface (orange peel effect). This effect is also common in the bending operations.
Extrusion: The most common defect in extrusion (known as the extrusion defect) arises
from the back flow of the material, pushing the end face of the billet into the core of the
product. Such a defect weakens the product since the surface layer is normally
contaminated by oxides. A centre burst is also possible with large h/L ratio, as shown
in figure(b). Such a centre burst may be avoided by extruding the product into a
pressurized chamber; this process is commonly known as extrusion against back
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pressure. Since the formation of dead zones tends to spoil the finish conical dies may be
used instead of the flat-face ones. Sometimes, the heat generated due to extrusion may
raise the temperature of the job, resulting in the development of surface cracks.
Q.6 (b) Solution:
Activity Normal time (days) Normal cost (`) Crash time (days) Crash cost (` ) Cost slope
1-2 4 1600 3 1800 200
1-3 9 2700 7 3500 400
2-3 3 1500 3 1500 0
3-4 6 2400 5 2800 400

3-5 7 4200 5 5000 400

4-5 3 1800 2 2400 600

4 6 15 15

2 4

4(3) 3(3) 6(5) 3(2)

1 3 5
9(7) 7(5)

0 0 9 9 18 18

Critical path = 1 – 3 – 4 – 5
Critical path duration = 9 + 6 + 3 = 18 days
Total cost = (1600 + 2700 + 1500 + 2400 + 4200 + 1800) + (18 × 450)
= `22300
We can crash activity along the critical path for reducing the project duration. Crashing
activity 1 – 3 by two days.

4 4 13 13

2 4

4(3) 3(3) 6(5) 3(2)

1 3 5
7 7(5)

0 0 7 7 16 16

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Now there are two critical paths.
1 – 2 – 3 – 4 – 5 = 4 + 3 + 6 + 3 = 16
1 – 3 – 4 – 5 = 7 + 6 + 3 = 16
Total cost after crashing = 1600 + 3500 + 1500 + 2400 + 4200 + 1800 + (16 × 450)
= `22200
Crashing activity 3 - 4 by one more day.

4 4 12 12

2 4

4 3 5 3

1 3 5
7 7

0 0 7 7 15 15

Critical paths = 1 – 2 – 3 – 4 – 5 = 4 + 3 + 5 + 3 = 15 days

= 1 – 3 – 4 – 5 = 7 + 5 + 3 = 15 days
Project cost = 1600 + 3500 + 1500 + 2800 + 4200 + 1800 + (15 × 450)
= `22150
For reducing critical path, activity 4 - 5 can be crashed by one day.

4 4 12 12

2 4

4 3 5 2

1 3 5
7 7

0 0 7 7 14 14

Critical path duration = 1 – 2 – 3 – 4 – 5 = 4 + 3 + 5 + 2 = 14 days

Critical paths
⇒ 1–3–5 Duration 14 days
⇒ 1–2–3–4–5 Duration 14 days
⇒ 1–2–3–5 Duration 14 days
⇒ 1–3–4–5 Duration 14 days

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Total project cost = 1600 + 3500 + 1500 + 2800 + 4200 + 2400 + (14 × 450)
= `22300
Crashed critical path duration = 14 days
Crash project cost = `22300
Ans: Project cost is minimum for 15 days. So optimum cost is `22150 and optimum
project duration is 15 days.

Q.6 (c) Solution:

1. Cartesian or Gantry Robot: When the arm of robot moves in a rectilinear mode,
that is in the directions x, y and z coordinates of the rectangular right handed
Cartesian coordinate system with the help of three prismatic joints. The workspace
has the shape of the rectangular box or prism.
• It is used for pick and place work, application of sealant, assembly operations
handling machine tools and arc welding.
• Gantry configuration is used for moving heavy loads precisely.
Disadvantages: It has limited manipulability and hence it is seldom used.

Cartesian Robot
2. Cylindrical Robot: When the arm of robot possesses one revolute and turn prismatic
joints. A robot whose arms move by θ, z and y, i.e. it has a base rotation, an elevation
and the reach respectively.
This type of robots are used for handling in casting machines and spot welding.
This type of robot have difficulties touching the floor near the base.
These robots are frequently used when the robot has to reach into small areas or
when working on cylindrical surfaces.

z y

Cylinderical Robot

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 Test No : 11 MECHANICAL ENGINEERING | 37
3. Spherical or Polar Robot: This robot consists of 2 revolute joints and one prismatic
joints; which represent the base rotation, elevation angles and reach respectively.
• It is used for machining, welding and spray painting etc.
Disadvantages:
• Its mechanical stiffness is lower than Cartesian and cylindrical robots.
• Wrist positioning accuracy decreases with increasing radial stroke.
• Complex construction.

y
φ

Polar Robot
4. Articulated or Anthropomorphic Robot (3R): In this robot arm the links are connected
by at least three revolute joints. Such robots are relatively simpler to fabricate and
maintain as the robots actuators are directly coupled through a set of rotary gear or
belt elements. It is used for assembly operations, die casting, fettling machines, gas
weld arc welding and spray painting. This type of robot needs comparatively smaller
workspace.
• Limitations of cylindrical robot is overcome in this construction as the arm end
point can reach the base point and below the base.
• This robot is very dexterous with work accuracy due to the pressure of revolute joints.
ψ φ

(a) Arm configuration (b) Workspace

5. SCARA Robot (2R, P): The SCARA acronym stands for Selective Compliance
Assembly Robot Arm or Selective Compliance Articulated Robot Arm.

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It is widely used in assembly operations in various industries.

This robot provides larger work envelope than the Cartesian, cylindrical or spherical
configurations. Despite having many advantages, the need of sophisticated controller
and more complex programming as compared to other configurations is a major
disadvantage of SCARA robot.

SCARA Robot (2R, P)

Q.7 (a) Solution:

Powder Metallurgy (PM) is the process of making desired solid shape of object from
fine powdered metals.
The process of powder metallurgy involves making very fine powdered material
(blending), pressing them into a desired shape (Compacting) and then heating the
compressed material into a controlled atmosphere to a temperature below the melting
point to bond the material (sintering) in the same steps as mentioned below.
The basic steps of Powder Metallurgy:
Step-I: Powder production
Step-II: Blending and mixing elemental or alloy powders
Step-III: Compacting
Step-IV: Sintering
Step-V: Finishing operation
Application of Powder Metallurgy;
1. In making brake lining, clutch lining
2. Small magnets
3. Ceramic tool tip
4. For making filters
5. Self lubricating bearing (oil) impregnation process is performed to improve self
lubricating property)
Advantages of Powder Metallurgy:
• Good tolerances and very good surface finish
• Fast process
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• Porosity in the material can be controlled
• Low material waste
• Physical properties can be easily control because it allows non-traditional alloy
combination.
Disadvantages of Powder Metallurgy:
• High equipment cost.
• Chances of powder deterioration when comes in contact with air.
• Flowability problem around sharp corners and varying thickness.
• Low density as compared to cast product.
• Process of making metallic powder is expensive.
• Part size is limited by the press.
Different methods of Powder Production:
1. Atomization: Atomization is the process of breaking molten metal into large number
of small droplets by rapidly freezing (Mechanically disintegration), before the
droplets comes into contact with each other.
2. Electrolysis Process: The desired metal is made as anode in an electrolytic cell in
such a way that it is dissolved by the electrolyte in the cell and then transported and
deposited on the cathode in a spongy or powder form.
The deposit material is then removed from cathode, washed and dried which is
subsequently used to form the metallic powder.
3. Reduction of Metal Oxide: Metal oxides are ground to a fine state and then these metal
oxide undergo reduction reaction by H2 or CO. It result in cake of sponge metal.
4. Agglomeration: This process is used to produce metal powder where constituents
are physically mixed together with an organic binder.
5. Grinding
6. Mechanical Pulverization
• Blending and Mixing: In this process different types of powders with desired
properties are mixed together to obtain the required properties. Some additives
are also used in this process which helps in blending and these additives also act as
lubricant. The lubricant is necessary to reduce the friction between particles and
surfaces of tool along which the powder must slide during compacting.
• The process of blending is done in rotating container called blender.
• Compacting: In this step, blended powders are pressed into the desired shape in
dies. The presses used for compacting process are driven by mechanical or hydraulic
action. The purpose of compaction process is to obtain the required shape, density
and particle to particle contact.
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• Sintering: In sintering process, the green compacts are heated in controlled

atmosphere furnace to a temperature that is below the melting point of the material.
• The heat is supposed to join the various grains (metal powders) into a single mass,
thus the required strength is developed.
• The strength in this process depends on the temperature and time. The powder
compaction is supposed to be in the furnace. Sometimes the cooling rate is also
controlled to obtain better mechanical properties.
• It results in reduction of brittleness and improvement of strength.
Finishing Operation:
1. Coining: It is a press working process on a sintered part to press details into its
surface.
2. Forging: In this process desired shape is given to sintered part at elevated
temperature.
3. Machining: Main objective of this process is in making threads, holes, slots etc. on
sintered part.
4. Sizing: In this process, dimensional accuracy of sintered part is improved.
5. Heat Treatment: It is used to improve strength and hardness of sintered part.
6. Plating/Colouring: To enhance the aesthetic value and resistance to wear and
corrosion, the sintered part is electroplated or coloured.
7. Joining: Two sintered parts are joined by typical joining methods like welding,
brazing etc.
8. Repressing: It is performed to increase the ductility and improve the mechanical
properties.
9. Infiltration: The pores(voids) of sintered part are filled with low melting point metal
by dipping the sintered part into low melting temperature metal liquid.
It decreases the porosity and improve the strength of components.
10. Impregnation: The only difference between infiltration and impregnation is that in
later the sintered part is kept in an oil bath. The oil will penetrate into the pores by
capillary action and remains there, this oil in the pores will be used for lubrication
of the component during actual working condition.
It promotes the self-lubricating property of sintered part and used in self-lubricating
bearings.
Pre-sintering: Generally, parts produced by powder metallurgy process are very hard.
For reduction in hardness and facilitate machining of component, pre-sintering is done
before sintering operation.

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Q.7 (b) Solution:
Metal Lubricant: These metal solids lubricants containing lamellar solids rely on film
transfer to achieve low friction. But continuous transfer of film may reduce the life of
component, therefore often "no lamellar solids" are added to lamellar solids low friction
characteristics. To achieve these objectives, holes are drilled in machine parts and those
holes are packed with solid lubricants. Various manufacturing techniques are used in
the production of metal-solid composites. These include powder metallurgy, infiltration
of porous metals, plasma spraying, and electrochemical deposition. One of the example
is molybdenum disulfide.
Strengths of metal lubricants:
1. High Load Carrying capacity
2. Low Friction
3. High temperature lubricant particularly in space.
Weaknesses of metal lubricants:
1. Moisture detrimental to performance
2. Film thickness ~ 15 μm.
Carbon and Graphite: Primary limitations, low tensile strength and lack of ductility of
bulk carbon make it good powder form solid lubricant. Their high thermal and oxidation
stabilities at temperatures of 500 to 600°C enable use of this solid lubricant at high
temperatures and high sliding speeds.
Carbon graphite seals are the most common example "Carbon and Graphite" solid
lubricant group. These seals transfer layers of graphite on mating surface and provide
low friction, but tight seal.
Strengths of graphite:
1. Moderate loads (< 275 MPa).
2. Low friction.
3. High temp. stability.
Weaknesses of graphite:
1. Corrosion.
2. Vacuum detrimental to performance.
Polymers: Polytetrafluoroethylene is a polymer produced from ethylene in which all
the hydrogen atoms have been replaced by fluorine atoms. Teflon is trade name of
PTFE given by Du Pont. Very light load applications. Poor adhesion of PTFE to other
materials is responsible for very low (< 0.1).
Strengths of Polymer lubricants: "High chemical stability, great chemical inertness,
because of carbon fluorine bonds.
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1. Very low surface energy, low friction (0.1), high P, low V.

2. Nontoxic- useful in pharmaceutical and food industries.
Weaknesses of Polymer lubricants:
1. Too soft, high wear rate.
2. Poor creep resistance, Low load capacity.
3. Poor thermal conductivity, high thermal expansion, temp. limit(250°C).
4. Vacuum is detrimental to performance.

Q.7 (c) Solution:

z1

θ1
α1 O2 y1
θ2 O1
y4
x1 – x2
z2 l2
O3 x3
z3 l3 O4

z4 x4

Link parameters Pair/joint variable cosθi sinθ1 cosαi sinαi

Link Pair/joint
ai αi θi di (Ci) (Si)

2 1 0 90° θ1 0 θ1 C1 S1 0 1
3 2 l2 0° θ2 0 θ2 C2 S2 1 0

4 3 l3 0° θ3 0 θ3 C3 S3 1 0

⎡C 1 −S1 0 0 ⎤ ⎡ cos 30° − sin 30° 0 0⎤

⎢S C1 0 0 ⎥ ⎢ sin 30° cos 30° 0 0⎥
1T
2 = ⎢ 1 ⎥=⎢ ⎥
⎢0 0 1 0⎥ ⎢ 0 0 1 0⎥
⎢ ⎥ ⎢ ⎥
⎣0 0 0 1⎦ ⎣ 0 0 0 1⎦

⎡0.866 −0.5 0 0 ⎤
⎢ 0.5 0.866 0 0 ⎥
⎢ ⎥
= ⎢ 0 0 1 0⎥
⎢ ⎥
⎣ 0 0 0 1⎦

⎡C 2 −S2 0 l2C 2 ⎤ ⎡ cos 60° − sin 60° 0 1 cos 60° ⎤

⎢S C2 0 l2S2 ⎥ ⎢ sin 60° cos 60° 0 1sin 60° ⎥
2
2T = ⎢ ⎥=⎢ ⎥
3 ⎢0 0 1 0 ⎥ ⎢ 0 0 1 0 ⎥
⎢ ⎥ ⎢ ⎥
⎣0 0 0 1 ⎦ ⎣ 0 0 0 1 ⎦

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⎡ 0.5 −0.866 0 0.5 ⎤

⎢0.866 0.5 0 0.866 ⎥
2T ⎢ ⎥
3 = ⎢ 0 0 1 0 ⎥
⎢ ⎥
⎣ 0 0 0 1 ⎦

⎡C 3 −S3 0 l3C 3 ⎤ ⎡ cos 45° − sin 45° 0 0.7 cos 45° ⎤

⎢S C3 0 l3S3 ⎥ ⎢ sin 45° cos 45° 0 0.7 sin 45° ⎥
3
3T = ⎢ ⎥=⎢ ⎥
4 ⎢0 0 1 0 ⎥ ⎢ 0 0 1 0 ⎥
⎢ ⎥ ⎢ ⎥
⎣0 0 0 1 ⎦ ⎣ 0 0 0 1 ⎦
⎡0.707 −0.707 0 0.495⎤
⎢0.707 0.707 0 0.495⎥
3T = ⎢ ⎥
4 ⎢ 0 0 1 0 ⎥
⎢ ⎥
⎣ 0 0 0 1 ⎦

⎡ 0.5 −0.866 0 0.5 ⎤ ⎡0.707 −0.707 0 0.495 ⎤

⎢0.866 0.5 0 0.866 ⎥ ⎢0.707 0.707 0 0.495 ⎥
2T = 2T 3T = ⎢ ⎥ ⎢ ⎥
4 3 4
⎢ 0 0 1 0 ⎥ ⎢ 0 0 1 0 ⎥
⎢ ⎥ ⎢ ⎥
⎣ 0 0 0 1 ⎦ ⎣ 0 0 0 1 ⎦

⎡0.5 × 0.707 − 0.866 × 0.707 −0.5 × 0.707 − 0.866 × 0.707 0 0.31883 ⎤

⎢ 0.965762 −0.258762 0 1.54217 ⎥
= ⎢ ⎥
⎢ 0 0 1 0 ⎥
⎢ ⎥
⎣ 0 0 0 1 ⎦
⎡ −0.258762 −0.965762 0 0.31883 ⎤
⎢ 0.965762 −0.258762 0 1.54217 ⎥
= ⎢⎢ ⎥
0 0 1 0 ⎥
⎢ ⎥
⎣ 0 0 0 1 ⎦

Q.8.(a) Solution:
A cryogenic treatment is the process of treating workpiece to cryogenic temperatures
(i.e. below-190°C) in order to remove residual stresses and improve wear resistance on
steels. In addition to seeking enhanced stress relief and stabilization, or wear resistance,
cryogenic treatment is also sought for its ability to improve corrosion resistance by
precipitating micro-fine eta carbides, which can be measured before and after in a part
using a quantimeter. The process has a wide range of applications from industrial tooling
to the improvement of musical signal transmission. Some of the benefits of cryogenic
treatment include longer part life, less failure due to cracking, improved thermal

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44 | ESE 2018 : MAINS TEST SERIES

properties, better electrical properties including less electrical resistance, reduced

coefficient of friction, less creep and walk, improved flatness, flatness, and easier
machining.
Cryogenic treatment is an add-on process to conventional heat treatment process in
material processing technology. It is a one-time permanent treatment which affects the
whole section of the component. It is not like the coatings of superior materials over
other metal surfaces that only affects the surface of components. Cryogenic treatments
are proved to be a good way to reduce the retained austenite content and improve the
performance of materials by improving its martensite structure. Objectives of cryogenic
treatment are to increase material’s strength, hardness, to improve machinability, cutting
properties of tools, to improve surface properties, electrical properties and magnetic
properties.
While steel was one of the first materials to undergo cryogenic treatment and the use of
this technique to increase the lifetime of machine tools is one of its major applications-
cryogenic treatment has been applied to a wide range of materials including aluminium,
brass, titanium, nickel alloys, some plastics and even carbon nanotubes.
Temper
hold
Temper
ramp up

Ambient
Temperatuer

Ramp Ramp
down up

–184°C (–300°F, 89 K) Typically

Typically Hold 4–10 h
27.31 mm (1.076 in.) typically 6-40h
4–10 h
Time

Typical cryogenic treatment cooling curve

Q.8 (b) Solution:

Step I: Converting the given problem in minimization problem by subtracting the highest
element of the table from all other elements.
19 39 47 11

9 40 21 23

22 20 32 3

4 0 3 20

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 Test No : 11 MECHANICAL ENGINEERING | 45
Step II: Subtracting the minimum element of the row from all other element of
corresponding row.
8 28 36 0

0 31 12 14

19 17 29 0

4 0 3 20

Step III: Subtracting the smallest element of each column from corresponding elements
of that column.
8 28 33 0
Opportunity
0 31 09 14
cost matrix
19 17 26 0

4 0 0 20

Step IV: Making allocations in opportunity cost matrix

8 28 33 0

0 31 9 14

19 17 26 0

4 0 0 20

Number of allocation < Size of matrix

⇒ So, Current solution is not optimum
Step V: Select the smallest element that do not have line through it. Subtract it from all
the element that do not have line through them and add it to every element at the
intersection of two line.

0 20 25 0

0 31 9 22

11 9 18 0

4 0 0 28

Number of allocation < Size of matrix

Step VI: Repeating the step V once again.

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0 11 16 0

0 22 0 22

11 0 9 0

13 0 0 37

Number of allocation = Size of matrix

Maximum sale = (60 + 58 + 79 + 76) × 105 rupees.
= `27.3 × 106 = `273 lakh =2.73 crore

Q.8 (c) Solution:

Pneumatic Control Valve:
• These type of control valves are exclusively used in Pneumatic systems.
• Pneumatic control valves are used to regulate the quantity of air flow and also used
to regulate the direction of air flow.
• Pneumatic control valves are classified based on the actuation method and on the
type of opening the valve.
Pneumatic Control Valves

Actuation Non-return type valves

Check valve
Shuttle valve
Quick exhaust valve
Dual pressure valve
PCV Electric

Solenoid
Non Return Type Control Valves:
• These types of valves are also called as direction control valves.
Check Valve:
1. It is basic type of non return type control valve.
2. If the inlet air pressure applies a force more than force offered by a internal
spring, then the check will be lifted up such that it can allows the air flow in a
particular direction.
3. Check valves offer minimum pressure drop compare to remaining non-return
type control valves.

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 Test No : 11 MECHANICAL ENGINEERING | 47

Check
Inlet Outlet

Shuttle Valve:
1. It is a dual check valve. It has two inlets and one outlet as shown in the figure.
2. The air flows through output channel if atleast air flows through one of the inlet.
3. These types of control valves are exclusively used in process industry as well as in
chemical industries to mix two different gases.
4. Shuttle valve performs “OR’ operation in pneumatic systems.
Shuttle
Inlet 1 Inlet 2 Outlet

1 0 1
Shuttle valve perform
Inlet 1 Inlet 2 0 1 1 OR
Logic
0 0 0

1 1 1
Outlet



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