Questions asked in Placements

Bosch:
1. Iron Carbide phase diagram
2. Laws of Thermodynamics
3. Modes of Heat Transfer
4. Types of casting and casting defects
5. Stress Strain Curve for ductile and brittle materials
6. PV for Carnot diagram
7. All 3 thermodynamics law and their applications
8. Limits, fits and tolerances
9. Why die casting? Why investment casting?
10. Rapid prototyping?
11. Stress strain curve for brittle and ductile; stainless steel and cast iron
12. BMD SFD of cantilever beam and simply supported
13. Hot and cold working and their structure
14. Recrystallisation temperature
15. Iron carbide phase diagram
16. Difference between tolerance and allowance.
17. SN curve
18. Power cycles
19. SFD and BMD of cantilever beam
20. Creep
21. PV state space power cycles
22. How to know if a diagram is first angle projection or third angle projection?
23. Rankine cycle PV and TS state space
24. Defects in welding
25. Mechanical advantage
26. Significance of back pressure
27. Principle of submarine
28. Difference between white smoke and black smokes from engines
29. Types of maintenance in industries
30. Orthographic projection
31. Why does a fluid boundary layer exist?
32. Quick return mechanism principle. What is the inversion of this mechanism?
33. Condition for floatation in stable equilibrium
34. Differences between impulse and radial turbines
35. How are Pelton wheels braked?
36. Why are tyres black?
37. Difference between transducer and sensor
38. Define resilience
39. What is bode plot?
40. What are thermoplastics?
41. Components of eutectoid steel
42. Addition of Molybdenum improves which property?
43. Why are taper provided on castings?
44. What is fullering?
45. What is the middle part of a three piece pattern in casting?
Caterpillar:
46. When an equal load is applied to a steel beam and a plastic beam. Which will have more stress?
47. Difference between true stress strain graph and engineering stress strain graph. Why don't we
prefer true stress strain graph over engineering stress strain graph?
48. What is the working principle of a pressure cooker?
Questions on Thermal conductivity and heat transfer coefficient
49. If you are cooling IC engine by water and keeping the volumetric flow rate of the water
constant without increasing the surface area what are the parameters which can be increased
or decreased so that the heat transfer rate increases
50. What are the different types of emissions and what is their origin? How to reduce those
emissions?
51. If you are designing a combustion chamber what would you be giving more preference to?
52. Difference between I beam and H beam. What is preferred in the given circumstances?

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53. FBD
Hooke’s law
54. Diesel and Otto cycles
55. TS and PV diagrams
56. Basics of Lean
57. 8 wastes in lean
58. Failure theories
59. Valve timing diagram
60. Friction welding
61. Electronic pass filter
62. Prandtl number
63. Entropy
64. Newtons laws
65. Types of modulus
66. Six bar linkage
67. SFD and BMD applications
Answers:

2.
0th Law of Thermodynamics:
The Zeroth Law of Thermodynamics states that if two systems are in thermodynamic
equilibrium with a third system, the two original systems are in thermal equilibrium with each
other. Basically, if system A is in thermal equilibrium with system C and system B is also in
thermal equilibrium with system C, system A and system B are in thermal equilibrium with each
other.
1st Law of Thermodynamics:
The First Law of Thermodynamics states that energy can be converted from one form to
another with the interaction of heat, work and internal energy, but it cannot be created nor
destroyed
ΔU=q+w
2nd Law of Thermodynamics:
The Second Law of Thermodynamics states that the state of entropy of the entire universe,
as an isolated system, will always increase over time. The second law also states that the changes
in the entropy in the universe can never be negative.
3rd Law of Thermodynamics:
When we are considering a totally perfect (100% pure) crystalline structure, at absolute
zero (0 Kelvin), it will have no entropy (S).

3. Modes of heat transfer

Conduction
Conduction takes place at a microscopic level. Atoms or molecules at higher temperature have
high levels of energy. Through vibration, this energy is passed on to neighboring atoms and
molecules. In other words, in conductive mode of heat transfer, vibrating atoms and molecules a
part of their energy. This kind of heat transfer can take place between two or more substances or
through the substance. Conduction can also take place when electrons move from one atom to
another.

Convection
Convection is a mode of heat transfer which takes place through the movement of collective
masses of heated atoms and molecules. Convection requires actual flow of material particles
whereas in conduction, the heat is transferred through vibration without the atoms or molecules
leaving their original position. In convection, heat transfer takes place through both diffusion and
advection. As convection requires the actual movement of the heated atoms/ molecules, it requires
presence of a fluid for heat transfer.
Radiation
Radiation is a mode of heat transfer which takes place through vacuum and hence, does not need
a physical medium. Radiation takes place either through vacuum or through a transparent medium.
In radiative mode, heat transfer takes place through photons present in the electromagnetic waves.
The random movement of atoms and molecules in heated substances results in emission of
electromagnetic waves which carry the heat to be transferred. The radiative heat transfer is
governed by Stephen- Boltzman law.

4. Types of casting and casting defects

Types:
• Sand Casting
• Other Expendable Mold Casting Processes
• Permanent Mold Casting Processes
• Foundry Practice
• Casting Quality
• Metals for Casting
• Product Design Considerations
Defects:

• Pinholes
• Subsurface blowhole
• Open holes
• Open shrinkage
• Closed shrinkage
• Cuts and washes
• Fusion

• Run out
• Swells
• Drops
• Rat tails, veins and buckles
• Metal penetration
• Hot tear/crack
• Hot/Hard spots

• Cold shut/lap
• Misruns
• Cold shots
• Slag inclusion (scab)
• Shift/mismatch
• Flash, fin and burrs
• Warping

5. stress strain ductile and brittle

6. PV diagram:
Otto

Diesel
Dual

Carnot
Brayton

9. why investment casting

The investment casting process or lost wax process, can produce the most intricate shapes.
Advantages of Investment casting
• Parts with extremely complex shapes and intricate features can be cast as a single piece
using investment casting
• With short length or shallow depth feature, thin sections down to 0.40 mm (0.015 in) can
be cast without cold shut defects
• Lost wax casting has excellent dimensional accuracy and tighter tolerances of 0.075 mm
(0.003 in) are easily achievable.
• Compared to similar manufacturing processes, Investment casting can achieve excellent
surface finish without any post-processing. Typically around 1.3 – 0.4 microns RMS Ra
• It offers almost unlimited freedom in terms of investment cast materials, but most common
materials used include Aluminium alloy, cast iron and non-ferrous alloys. The process is
particularly attractive for high-temperature alloys.
• Draft on walls are not required but if a master die is used to make wax patterns then draft
on the face would help the pattern making process easier.
• Since there are no parting lines, the cast would not have any flash. But the wax patterns
might have parting lines from the master die.
• Additional machining can be eliminated or reduced and allowance of as little as 0.4 to 1
mm (0.015 to 0.040 in.) usually enough.
• Excellent dimensional precision can be achieved in combination with very smooth as-cast
surfaces. These capabilities are especially attractive when making products from the high-
melting temperature, difficult-to-machine metals that cannot be cast with plaster- or metal
mould processes.
• The wax used can usually be recovered for reuse.
10. Rapid prototyping:
Rapid prototyping is the fast fabrication of a physical part, model or assembly using 3D computer
aided design (CAD). The creation of the part, model or assembly is usually completed using
additive manufacturing, or more commonly known as 3D printing.
Commonly adopted methods:
Stereolithography (SLA) or Vat Photopolymerization
This fast and affordable technique was the first successful method of commercial 3D printing. It
uses a bath of photosensitive liquid which is solidified layer-by-layer using a computer-controlled
ultra violet (UV) light.

Selective Laser Sintering (SLS)

Used for both metal and plastic prototyping, SLS uses a powder bed to build a prototype one layer
at a time using a laser to heat and sinter the powdered material. However, the strength of the parts
is not as good as with SLA, while the surface of the finished product is usually rough and may
require secondary work to finish it.

12. BMD and SFD

Simply supported:
Cantilever
Over hanging
14. recrystallization
16. Difference between tolerance and allowance.

Tolerance:
• The difference between the upper limit and lower limit is called tolerance.
• The amount of error that can be tolerated can be is represented by limits on the drawing.
• Tolerance is the limit of random (unintentional) deviation of a dimensions from nominal
values.
• Metal parts are used in many numbers in assembles and manufacturing industries. These
parts must have to fit each other with comfortably.

Allowance:
• Allowance is calculated as the difference between the maximum shaft size and minimum
hole size is known as allowance.
• It is a amount of designed (intentional) deviation between two mating parts of dimensions
in a fit.
• In a clearance fit it is have a minimum clearance and is positive allowance.
• In an interference fit it is have a maximum interference and is negative allowance.
• Allowance is the difference between the dimensions of hole and shaft.

15. iron carbide

Reactions:
Peritectic: L+ δ = γ
at T=1493oC and 0.18wt%C
Eutectic: L = γ +Fe3C
at T=1147oC and 4.3wt%C
Eutectoid: γ = α +Fe3C
at T=727oC and 0.77wt%C

phases:
δ ferrite:
• Bcc structure
• Paramagnetic
γ austenite:
• Fcc structure
• Non‐magnetic
• Ductile
α ferrite
• Bcc structure
• Ferromagnetic
• Fairly ductile
Fe3C cementite
• Orthorhombic
• Hard, brittle

Phases in Fe–Fe3C Phase Diagram

α‐ferrite‐solid solution of C in BCC Fe
•Stable form of iron at room temperature.
•Transforms to FCC g‐austenite at 912 °C
γ‐austenite‐solid solution of C in FCC Fe
•Transforms to BCC δ‐ferrite at 1395 °C
•Is not stable below the eutectic temperature (727 °C) unless cooled rapidly.
δ‐ferritesolid solution of C in BCC Fe
•It is stable only at T, >1394 °C. It melts at 1538 °C
Fe3C (iron carbide or cementite)
•This intermetallic compound is metastable at room T. It decomposes (very slowly, within
several years)into α‐Fe and C (graphite) at 650 ‐700 °C
Fe‐C liquid solution
• C is an interstitial impurity in Fe. It forms a solid solution with α, γ, δ phases of iron
• Maximum solubility in BCC α‐ferrite is 0.022 wt% at 727 °C. BCC: relatively small
interstitial positions
• Maximum solubility in FCC austenite is 2.14 wt% at 1147 °C‐FCC has larger interstitial
positions
• Mechanical properties: Cementite (Fe3C is hard and brittle: strengthens steels). Mechanical
properties also depend on microstructure: how ferrite and cementite are mixed.
• Magnetic properties: α‐ferrite is magnetic below 768 °C, austenite is non‐magnetic

17. SN Curve
Endurance Limit
Certain materials have a fatigue limit or endurance limit which represents a stress level below
which the material does not fail and can be cycled infinitely.
If the applied stress level is below
the endurance limit of the material, the structure is said to have an infinite life.

22. First and Third angle projections

24. defects in welding

External Welding Defects:

1. Weld Crack
2. Undercut
3. Spatter
4. Porosity
5. Overlap
6. Crater

Internal Welding Defects:

1. Slag Inclusion
2. Incomplete Fusion
3. Necklace cracking
4. Incompletely filled groove or Incomplete penetration

Causes and remedies are given in detail in this link: https://www.theweldingmaster.com/welding-

defects/

Mechanical advantage
Mechanical advantage is a measure of the ratio of output force to input force in a system, used to
analyze the forces in simple machines like levers and pulleys.

MA = effort (input) distance/ resistance (output) distance = resistance force/ effort force
Significance of back pressure
Residual pressure on the exhaust side of a steam-engine piston against which the steam on the
intake side must work

Principle of submarine

The submarine operates using the Archimedes' principle by manipulating the buoyancy.

The buoyancy is controlled by the ballast tank system. A submarine resting on the surface has
positive buoyancy, which means it is less dense than the water around it and will float. At this
time, the ballast tanks are mainly full of air. To submerge, the submarine must have negative
buoyancy. Vents of the ballast tanks are opened.
Seawater coming in through the flood ports forces air out the vents, and the submarine begins to
sink. The submarine ballast tanks now filled with seawater is denser than the surrounding water.
The exact depth can be controlled by adjusting the water to air ratio in the ballast tanks.
Submerged, the submarine can obtain neutral buoyancy. That means the weight of the submarine
equals the amount of water it displaces. The submarine will neither rise nor sink in this state. To
make the submarine rise again, compressed air is simply blown into the tanks forcing the seawater
out. The submarine gains positive buoyancy becomes less dense than the water and rises.

How are pelton wheels braked

Why are tyres black

1. During the Vulcanization process carbon black along with sulphur is mixed into the rubber,
this strengthens the molecular bond of the rubber and makes it more sturdy, wear resistant and
durable, the reason of adding carbon black is because carbon black is available cheaper then
any other material.
2. Black color is good absorber of heat and can absorb the sunrays better, when a vehicle is out
in open under the sun, the wear and tear will be very minimal as compared to any other color.

42. Addition of molybdenum improves which property

Increases hardenability and strength particularly at high temperatures and under dynamic
conditions