ESE-2018 Mains Test Series: Mechanical Engineering Test No: 8

Detailed Solutions
ESE-2018 Mechanical Engineering

Mains Test Series Test No : 8
Section A : Machine Design + Mechatronics and Robotics
Q.1.(a) Solution:
Microprocessor
Output Input
Register array
ALU
System Bus
Memory
Control
Figure: Block diagram of a microcomputer
The microprocessor consists of the following three segments:

1. Arithmetic/logic unit (ALU): In this area of microprocessor, computing functions
are performed on data. The ALU performs airthmetic operations such as addition
and subtraction, and logic operations such as AND, OR and exclusive OR. Results
are stored either in registers or in memory or sent to output devices.
2. Register unit: This area of the microprocessor consists of various registers. The
registers are used primarily to store data temporarily during the execution of a
program. Some of the registers are accessible to the user through instructions.
3. Control unit: The control unit provides the necessary timing and control signals
to all the operations in the microcomputer. It controls the flow of data between
the microprocessor and peripherals including memory.
Test No : 8 MECHANICAL ENGINEERING | 11
Uses/Application areas of microprocessor
– Instrumentation application
– Process control
• Instrumentation
• Monitoring and control
• Data acquisition
– Medical electronics:
• Patient monitoring in ICU
• Pathological analysis
• Measurement of parameters like blood pressure and temperature
– High level language computers
– Home entertainment and games
– Computer peripheral control
– Control of automation and continuous processes
– Inventory control system, pay roll banking etc.
Q.1.(b) Solution:
Bending moment, M b = 600 kNm = 600 × 106 Nmm
UTS, Sut = 550 MN/m2 550 N/mm2
Yield point, Syt = 380 MN/m2 = 380 N/mm2
Notch sensitivity factor, q = 0.8
Surface finish factor, ka = 0.77
for 90% reliability, kc = 0.897
size factor, kb = 0.75
⎛ rf ⎞ 8
We have ⎜ ⎟ = = 0.02667
⎝ d ⎠ 300
⎛ 2.6 − 2.05 ⎞
kt = 2.05 + ⎜ ⎟ × (0.05 − 0.02667 ) = 2.5633
⎝ 0.05 − 0.025 ⎠
Fatigue stress concentration factor, kf = 1 + q(kt – 1)
= 1 + 0.8(2.5633 – 1) = 2.25
1 1
kd = = = 0.443
k f 2.25
Se = kakbkc kd Se′
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12 | ESE 2018 : MAINS TEST SERIES
= 0.77 × 0.75 × 0.897 × 0.443 × 210 (Se′ = 210 N/mm2)

= 48.33 N/mm2
32 Mb 32 × 600 × 106
σb = = = 226.354 N/mm2
πd 3 π× ( 300 )
3
0.9 Sut = 0.9 × 550 = 495 N/mm2

log10(0.9 Sut) = log10(495) = 2.6946
log10(Se) = log10(48.33) = 1.6842
log10(σb) = log10(226.354) = 2.3548
The S-N curve for shaft is shown below:
log10 Sf
2.6946 A
E F
2.3548
1.6842 D C B
3 4 5 6 log10N
log10N
DB × AE
Fatigue life of shaft, EF =
AD
( 6 − 3 )( 2.6946 − 2.3548 )
= ( 2.6946 − 1.6842 ) = 1.009
Therefore, log10N = 3 + EF
= 3 + 1.009 = 4.009
N = (10)4.009
N = 10209.4 cycles Answer
Q.1.(c) Solution:
PLCs are specialized industrial devices for interfacing input/output and controlling
analog and digital devices.
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Input Output
PLC (to devices)
(from devices)
Control program
(i) They are designed with a small instruction set suitable for industrial control
applications.
(ii) They are usually programmed with “ladder logic”, which is graphical method
of laying out the connectivity and logic between system inputs and outputs.
(iii) They are designed with industrial control and industrial environments
specifically in focus. Therefore, in addition to being flexible and easy to
program, they are robust and relatively immune to external interference.
(iv) It is a “digital electronic device” that uses a programmable memory to store
instructions and to implement functions such as logic sequencing, timing,
counting and arithmetic in order to control machines and processes.
Special features of PLCs:
(i) The interfacing for inputs and outputs is inside the controller.
(ii) They have an easily understood programming language. Programming is
mainly concerned with logic and switching operations.
(iii) Rugged and designed to withstand vibrations, temperature, humidity and
noise.
Advantages of a PLC:
(i) Low cost
(ii) Easy to install
(iii) Ensure increased productivity
(iv) Faster operational speed
(v) Provides high reliability and easier maintenance
(vi) Can withstand harsh industrial environment/manufacturing environment.
(vii) Provides constancy in manufacturing.
(viii) Can input/output both analog and digital signals.
(ix) Reduced cost of scrap and rework since the user/designer can change the PLC
program without changing any hardware or scraping the present hardware.
(x) Small size.
(xi) PLC modulus can be added, depending upon the input/output requirements
(xii) Easier troubleshooting.
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Q.1.(d) Solution:
h = 15 mm, l = 3.5 m = 3500 mm, A = 600 mm2,
δl = 3 mm, E = 200 × 103 N/mm2
Bar
W
l
Collar
δl
From the energy equilibrium:

Strain energy = loss in PE by weight
1
P × δl = W(h + δl )
2
Taking P = σi A and
σi × l
δl =
E
We find instantaneous stress as
W⎛ 2 hAE ⎞
σi = ⎜1+ 1+ ⎟ ...(i)
A⎝ Wl ⎠
E (δl ) 200 × 10 3 × 3
σi = = = 171.43 N/mm2 Answer
l 3500
Now, from equation (i):
⎛ 2 × 15 × 600 × 200 × 103 ⎞

171.43 × 600 = W ⎜⎜ 1 + 1 + ⎟⎟
⎝ W × 3500 ⎠
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102858 1028571.43
= 1+ 1+
W W
2
⎛ 102858 ⎞ 1028571.43
⎜ − 1⎟ = 1+
⎝ W ⎠ W
2
⎛ 102858 ⎞ 2 × 102858 1028571.43
⎜ ⎟ +1− = 1+
⎝ W ⎠ W W
(102858 )2 1234287.43
=
W2 W
( 102858 )2
W = = 8571.56 N Answer
1234287.43
Q.1.(e) Solution:
A cubic polynomial has the form
θ(t) = a1 + a2t + a3t 2 + a4t3
θf
θi
ti tf
Curves connecting initial and final point
The velocity and acceleration can be expressed by
θ (t f ) = a2 + 2a3t + 3a4t 2
θ (t ) = 2a3 + 6a4t
When a link moves, it starts from rest and stops at rest, hence the initial and final velocities
have to be zero at initial time ti and final time tf .
θ ( 0 ) = 0
θ (t f ) = 0
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Hence combining the two velocity constraints and two position constraints (start position
and end position) and using equations.
θi = a1
θf = a1 + a2tf + a3tf 2 + a4tf3
0 = a2
0 = a2 + 2a3tf + 3a4 tf2
Solving above four equations, we get
a1 = θi
a2 = 0
3
a3 = t 3 (θ f − θi )
f
In the given problem, θi = 0°, θf = 60°, time, t = 5 seconds

a1 = 0
a2 = 0
3 3
a3 =
t2
(θ f − θi ) = 25 × (60 − 0 ) = 7.2
2 2
a4 = − 3 (θ f − θi ) = − × ( 60 − 0 ) = −0.96
t 125
The required cubic polynomial is given by
θ(t) = 7.2t 2 – 0.96 t 3 Answer
Q.2 (a) Solution:

Given, Sut = 720 N/mm2, Syt = 480 N/mm2, kW = 25, n = 480 rpm kb = kt = 1.4, PCD = 325
mm, Pulley diameter = 475 mm
Step 1: Permissible shear stress
0.30 Syt = 0.30(480) = 144 N/mm2
0.18 Syt = 0.18(720) = 129.6 N/mm2
The lower of the two values is 129.6 N/mm2
Step 2: Torsional moment
The torque transmitted by the shaft is given by,
60 × 10 6 (kW) 60 × 10 6 (25)
Mt = =
2 πn 2 π × 480
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= 497359.1972 N-mm.
Step 3: Bending moment
(P1 – P2) × 237.5 = 497359.1972
∴ (P1 – P2) = 2094.1439 N (a)
Also, P 1 = 3P2 (b)
From equation (a) and (b),
P 1 = 3141.215 N and P2 = 1047.071 N
∴ (P1 + P2) = 4188.286 N
325
Pt × = 497359.1972
2
Pt = 3060.7 N
Pr = Pttan(20°) = 3060.7 tan(20°) = 1114 N
The forces and bending moments in vertical and horizontal planes are shown in below
figure. The maximum bending moment in at C.
Vertical plane
1537 1114 4188.286
6839
5383107
1465800
Horizontal plane
3060.7
1530.35 1530.35
535622.5
350 350 350
At C, Mb = 1465800 N-mm; Mt = 497359.1972 N-mm
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Step 4: Shaft diameter

16
d3 ≥ π τ ( kb Mb )2 + ( kt Mt )2
max
16 2 2
≥ π(129.6) (1.4 × 1465800) + (1.4 × 497359.1972)
or d ≥ 43.99 mm
d 44 mm Answer
Q.2 (b) Solution:

Given: b = 350 mm; τ = 20 mm; σt = 90 MPa = 90 N/mm2; τ = 60 MPa = 60 N/mm2;
σc = 150 MPa = 150 N/mm2
1. Diameter of rivet
We know that the diameter of rivet hole,
d = 6 t + 2 = 6 20 + 2 = 28.8 mm
The standard diameter of rivet hole (d) is 29 mm.

2. Number of rivets
Let n = Number of rivets
We know that the maximum pull acting on the joint,
Pt = (b – i)t × σt = (350 – 29)20 × 90 = 577800 N
Since, the joint is double strap butt joint, therefore the rivets are in double shear. Assume
that the resistance of the rivet in double shear is 1.875 times than in single shear.
∴Shearing resistance of one rivet,
π π
Ps = 1.875 × × d 2 × τ = 1.875 × (29)2 × 60 = 74308 N
4 4
and crushing resistance of one rivet,
Pc = d × t × σc = 29 × 20 × 150 = 87000 N
Since the shearing resistance is less than crushing resistance, therefore number of rivets
required for the joint,
Pt 577800
n = = = 7.77
Ps 74308
∴ n = 10 (for lozenge joint)
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3. The arrangement of rivets in below figure
1 2 3 4
95
350
45 75 75 75 45 45 75 75 75 45 (All dimensions in mm)

1 2 3 4 15
20
15
4. Thickness of butt straps

We know that the thickness of butt straps,
t1 = 0.75t = 0.75 × 20 = 15 mm
First of all, let us find the resistance along the sections 1-1, 2-2, 3-3 and 4-4.
At section 1-1, there is only one rivet hole.
∴ Resistance of the joint in tearing along 1-1,
Pt1 = (b – d)t × σt = (350 – 29)20 × 90 = 577800 N
At section 2-2,
There are two rivet holes. In this case the tearing of the plate will only take place if the
rivet at section 1-1 (in front of section 2-2) gives way:
Pt2 = (b – 2d)t × σt + Shearing strength of one rivet in front
= (350 – 2 × 29)20 × 90 + 74308= 599908 N
At section 3-3,
There are two rivet holes. The tearing of the plate will only take place if the rivet at
section 1-1 and two rivet at section 2-2 gives way:
∴ Resistance of the joint in tearing along 3-3,
Pt3 = (b – 3d)t × σt + Shearing strength of 3 rivet in front
= (350 – 3 × 29)20 × 90 + 3 × 74308 = 696324 N
Similarly, resistance of the joint in tearing along 4-4,
Pt4 = (b – 4d)t × σt + Shearing strength of 6 rivet in front
= (350 – 4 × 29)20 × 90 + 6 × 74308 =867048 N
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Shearing resistance of all the 10 rivets,

Ps = 10 × 74308 = 743080 N
and crushing resistance of all the 10 rivets,
Pc = 10 × 87000 = 870000 N
The strength of the joint is the least of Pt1, Pt2, Pt3, Pt4, and Pc
∴ Strength of the joint = 577800 N along section 1-1
We know the strength of the un-riveted plate,
P = b × t × σt = 350 × 20 × 90 = 630000 N
S t rength of the joint 577800

η = Strength of the un − riveted plate = 630000
= 0.917 or 91.7%
6. Pitch of rivets, p = 2d + 5 mm = 2 × 29 + 5 = 92 say 95 mm
7. Marginal rivets, m = 1.5d = 1.5 × 29 = 43.5 say 45 mm
8. Distance between the rows of rivets,
= 2.5d = 2.5 × 29 = 72.5 say 75 mm
Q.2.(c) (i) Solution:
P = 30 kN = 30 × 103 N, τmax = 75 MPa = 75 N/mm2,
l = 100 mm, b = 150 mm, e = 600 mm
Let s = size of the weld and
t = throat thickness
Throat area, A = t(2b + 2l)
= 0.707 s(150 + 100) × 2 = 353.55s mm2
P 30 × 103 84.86
Direct shear stress, τ = = = N/mm2
A 353.5 s s
Bending moment, M = Pe = 30 × 103 × 600 = 18 × 106 Nmm
⎛ b2 ⎞
Section modulus, z = t ⎜ bl + ⎟
⎝ 3 ⎠
⎛ ( 150 )2 ⎞
= 0.707 s ⎜ 150 × 100 + ⎟ = 15907.5 s mm3
⎝ 3 ⎠
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M 18 × 106 1131.54
Bending stress, σb = = = N/mm2
z 15907.5 s s
Maximum shear stress (τmax):
1
τmax = σb2 + 4 τ2
2
2 2
1 ⎛ 1131.54 ⎞ ⎛ 84.86 ⎞
75 = ⎜ ⎟ + 4⎜ ⎟
2 ⎝ s ⎠ ⎝ s ⎠
2 2
⎛ 1131.54 ⎞ ⎛ 84.86 ⎞
(150)2 = ⎜ ⎟ + 4×⎜ ⎟
⎝ s ⎠ ⎝ s ⎠
s 2 = 58.1863
∴ size of the weld, s = 7.628 mm answer
Q.2.(c) (ii)
Given: n2 = 1450 rpm, m = 2 kg, z = 4, rd = 145 mm, rg = 112 mm, μ = 0.28, Ps = 750 N.
Step I: Speed at which the engagement begins
The spring force is given by,
mω12 rg
Ps =
1000
2ω12 (112 )
or 750 =
1000
∴ ω1 = 57.863 rad/s
60ω1 60 ( 57.863)
n1 = = = 552.55 rpm ...(i)
2π 2π
Step II: Power transmitted by the clutch
2 πn2 2 π (1450 )
ω2 = = = 151.843 rad/s
60 60
μmrg rd z (ω22 − ω12 )

From eq. Mt =
1000
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0.28 ( 2 )( 112 ) (145) ( 4 ) ( 151.8432 − 57.8652 )

∴ Mt =
1000
= 716935.92 Nmm
2 πn2 Mt 2 π ( 1450 )(716935.92 )

kW = 6
=
60 × 10 60 × 106
= 108.486 kW ...(ii)
Q.3.(a) Solution:
y
θ3
θ2
θ1
x
The planar manipulator and its home configuration
l3
θ3 l3 sin θ1 + θ2 + θ3
θ1 + θ2
l2
θ2 l2 sinθ1 + θ2
θ1
l1
l1 sinθ1
θ1
l1 cosθ1 l2 cosθ1 + θ2 l3 cosθ1 + θ2 + θ3 x
Using trigonometry to derive the kinematic equations
General motion (x, y) will be given by
⎛x⎞ ⎛ cos (θ1 + θ2 + θ3 ) − sin (θ1 + θ2 + θ3 ) kx ⎞ ⎛ l1 + l2 + l3 ⎞

⎜ ⎟
⎜ ⎟
y ⎜ sin ( θ1 + θ2 + θ3 ) cos ( θ1 + θ2 + θ3 ) ky ⎟ ⎜ 0 ⎟
⎜ ⎟ = ⎜ ⎟
⎜ 1⎟
⎝ ⎠
⎜
⎝ 0 0 1 ⎟⎠ ⎜⎝ 0 ⎟
⎠
for the present configuration,
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x = l1 cosθ1 + l2cos(θ2 + θ1) + l3cos(θ1 + θ2 + θ3)
y = l1 sinθ1 + l2sin(θ1 + θ2) + l3 sin (θ1 + θ2 + θ3)
⎛π⎞ ⎛π⎞ ⎛π⎞

(i) x = 2 cos ⎜ ⎟ + 2 cos ⎜ ⎟ + 1 cos ⎜ ⎟ = 1 + 3
⎝6⎠ ⎝3⎠ ⎝2⎠
⎛π⎞ ⎛π⎞ ⎛π⎞

y = 2 sin ⎜ ⎟ + 2 sin ⎜ ⎟ + sin ⎜ ⎟ 2 + 3
⎝6⎠ ⎝3⎠ ⎝2⎠
π π π π
φ = + + =
6 6 6 2
⎛π⎞ ⎛ 11π ⎞ ⎛ 13π ⎞

(ii) x = 2 cos ⎜ ⎟ + 2 cos ⎜ ⎟ + cos ⎜ ⎟
⎝2⎠ ⎝ 6 ⎠ ⎝ 6 ⎠
= 2cos90° + 2cos330° + cos390°
3 3 3 3
= 0+ ×2+ =
2 2 2
⎛π⎞ ⎛ 11π ⎞ ⎛ 13π ⎞
y = 2 sin ⎜ ⎟ + 2 sin ⎜ ⎟ + sin ⎜ ⎟
⎝2⎠ ⎝ 6 ⎠ ⎝ 6 ⎠
= 2sin 90° + 2sin330° + sin390°
⎛ 1⎞ 1 3
= 2 + 2⎜− ⎟ + =
⎝ 2⎠ 2 2
π 4 π π 13π
φ = + + =
2 3 3 6
⎛ π⎞ ⎛π⎞ ⎛π⎞ 3 3
(iii) x = 2 cos ⎜ − ⎟ + 2 cos ⎜ ⎟ + cos ⎜ ⎟ =
⎝ 6⎠ ⎝2⎠ ⎝6⎠ 2
⎛ π⎞ ⎛π⎞ ⎛π⎞ 3
y = 2 sin ⎜ − ⎟ + 2 sin ⎜ ⎟ + sin ⎜ ⎟ =
⎝ 6⎠ ⎝2⎠ ⎝6⎠ 2
π 2π π π
φ = − + + =
6 3 3 6
NOTE: We can observe that (ii) and (iii) gives the same answer, hence they are the two
different postures for this position.
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Q.3.(b) Solution:
x1 x2
SF1 Spring force due to

k2 (SF2) SF2
M1 M1 F
Damping force due to
DF2
B2 (DF2)
DF1
FBD for M1 FBD for M2
from a free body diagram, spring forces and damping forces can be determined. Analyzing
free body diagram for mass M 1, we get
SF1 = k1x1
SF2 = k2(x1 – x2)
dx1
DF1 = B1
dt
d ( x1 − x2 )
DF2 = B2
dt
from Newton’s second law of motion :
Mass × acceleration = – SF1 – DF1 – SF2 – DF2
d 2 x1 dx1 d ( x1 − x2 )
M1
2 = −K1x1 − B1 − k2 ( x1 − x2 ) − B2
dt dt dt
d 2 x1 dx1 dx
M1 + ( B1 + B2 ) + ( k1 + k2 ) x = B2 2 + k2 x2 ...(i)
2 dt dt
dt
Taking Laplace transform of equation (i), we get
[M1s2 + (B1 + B2)s + (k1 + k2)]X1(s) = [B2s + k2]X2(s) ...(ii)
from free body diagram of M2, we get
Mass × acceleration = F + SF2 + DF2
d 2 x2 d ( x1 − x2 )
M2
2 = k2 ( x1 − x2 ) + B2 +F
dt dt
d 2 x2 dx2 dx
M2 + B2 + k2 x 2 = k1 x1 + B2 1 + F ...(iii)
2 dt dt
dt
Taking Laplace transform of equation (iii), we get
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[M2S 2 + B2S + k2]X2(s) = [k2 + B2s] + F(s) ...(iv)
Substituting the value of X2(s) from equation (ii), we can relate X1(s) and F(s) as
⎢
{ 2 1 2 }{( 2 1 2 )
⎡ M s 2 + ( B + B ) + ( k + k ) M s2 + B s + k − k + B s 2
1 1 (1 2) }⎤⎥ X (s ) = F(s)
⎢⎣ k2 + B2 s ⎥⎦ 1
NOTE : following laplace transform formula has been used :
⎡d ⎤
(i) L ⎢ f (t )⎥ = sF(s) – f(0)
⎣ dt ⎦
⎡ d2 ⎤ df (0 )
(ii) L⎢ f (t )⎥ = s 2F(s) – sf(0) –
⎣ dt 2 ⎦ dt
(iii) For function with zero initial values, the transformation simplifies to
⎡ df (t ) ⎤
L⎢ = sF(s)
⎣ dt ⎥⎦
⎡ d 2 f (t ) ⎤
L⎢ ⎥ = s2F(s)
⎣ dt 2 ⎦
⎡ d n f (t ) ⎤
L⎢ ⎥ = snF(s)
⎣ dt n ⎦

Range : It is difference between minimum and maximum values of a quantity, for which
and instrument is designed to measure the parameters. E.g.: Load cell may have the
range varying from 10 kN to 100 kN.
Span: It is the difference between the maximum and minimum values of the quantity to
be measured.
Span = maximum value of the input – minimum value of the input
Error: The deviation of the true value from the measured value of called error.
That is,
Error = measured value – true value.
Accuracy: It may be defined as the ability of an instrument to respond to a true value of
a measured variable under the reference conditions. It refers to how closely the measured
value agrees with the true value. The accuracy of an instrument can be specified in the
following way:
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(i) Accuracy as a “percentage of full scale reading”.

(ii) Accuracy as a “percentage of true value”.
(iii) Accuracy as a “percentage of span”.
Precision: It is defined as the degree of exactness for which an instrument is
designed or intended to perform. It refers to the repeatability or consistency of
measurements when the measurements are carried out under identical conditions
at short travels of time. It can also be defined as the ability of the instrument to
reproduce a group of measurements of the same measured quantity under the
same conditions.
Q.3.(c) (ii)Solution:
Step 1 : Combine two blocks in parallel (fee-forward control)
1.5
2 + 1.5 = 3.5
+
2
Step 2 : Combine two blocks in series:
3.5 10 3.5 × 10 = 35
Step 3 : Closed loop transfer function (CLTF)
35
7.77
1.5
G (s )
CLTF =
1 + G (s ) H (s )
35 34
= = = 7.77 Answer
1 + 35 × 0.1 4.5
Q.4.(a) (i) Solution:

P = 150 kW, N = 100 rpm, CE = 0.1, D = 2 m, R = 1 m
ρ = 7200 kg/m3, ω1 – ω2 = ± 2.5% ω
ω1 − ω2
cs = = ± 2.5% or 0.05
ω
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2 πN 2 π × 100
ω = = = 10.47 rad/s
60 60
P × 60
Work done by flywheel per stroke =
N ×2
150 × 10 3 × 60
= = 45000 Nm
100 × 2
Coefficient of fluctuation of energy,
Maximum fluctuation of energy ( ΔE )
CE = Workdone/cycle
ΔE = CE × Workdone/cycle
= 0.1 × 45000 = 4500 Nm
Since 5% of the rotational inertia is provided by hub and spokes, therefore the maximum
fluctuation of energy of the flywheel rim will be 95% of the flywheel.
(ΔE)rim = 0.95 × 4500 = 4275 Nm
(ΔE)rim = mR 2ω avg2 Cs
4275
m = 2 779.96 kg Answer
12 × (10.47 ) × 0.05
mass = cross section area × perimeter × density
779.96 779.96
A = = = 0.01724 m2 Answer
2 πR × 7200 2 π× 7200
Q.4.(a) (ii) Solution:

σ 1 = 420 MPa, σ2 = 180 MPa, σ3 = 0
Equivalent stress as per Von-mises theory:
⎛ ( σ − σ )2 + (σ − σ )2 + (σ − σ )2 ⎞
σe = ⎜ 1 2 2 3 3 1 ⎟
⎝ 2 ⎠
⎛ ( 420 − 180 )2 + ( 180 − 0 )2 + ( 0 − 420 )2 ⎞

= ⎜ ⎟
⎝ 2 ⎠
= 364.966 MPa
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600
Factor of safety, FOS = = 1.644
364.966
As per maximum normal stress theory, σe = σ1 = 420 MPa
600
FOS = = 1.4286 Answer
420
Maximum shear stress theory:
⎧ σ1 − σ 2 σ 2 − σ 3 σ 1 − σ 3 ⎫
τmax = Maximum of ⎨ , , ⎬
⎩ 2 2 2 ⎭
⎧ 420 − 180 180 − 0 420 − 0 ⎫

= Max of ⎨ , , ⎬
⎩ 2 2 2 ⎭
= Max. of {120, 90, 210}
τmax = 210 MPa = τe
σ ys 300
FOS = = = 1.4286 Answer
2 τe 210
(ii) σ 1 = 0, σ2 = – 180 MPa, σ3 = – 420 MPa
(0 + 180 )2 + ( 420 − 180 )2 + (0 + 420 )2

Von-mises theory, σe =
2
σe = 364.96
600
FOS = = 1.644 Answer
364.96
Maximum normal stress theory,σe= σ1 = 0
600
FOS = = ∞ (In tension)
0
600
In compression, FOS = = 1.4286 Answer
420
Maximum shear stress theory :
σ1 − σ 2 0 + 180
τ12 = = = 90 MPa
2 2
σ 2 − σ 3 −180 + 420
τ23 = = = 120 MPa
2 2
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σ1 − σ 3 0 + 420
τ13 = = = 210 MPa ← τmax
2 2
σ ys
FOS =
2 τmax
300
= = 1.4286 Answer
210
Q.4.(b) (i) Solution:
The different parts of the 8051 microcontroller are as follows:
1. CPU which includes program counter, ALU, working registers and block circuit.
2. 8-bit CPU with registers (the accumulator) and B.
3. 16-bit program counter (PC) and data pointer (DPTR)
4. 8-bit program status word (PSW)
5. 8-bit stack pointer (SP)
6. Internal ROM of 4 kB.
7. Internal RAM of 128 bytes
8. Four register banks each containing 8 registers:
– sixteen bytes, which may be addressed at bit level.
– eighty bytes of general purpose data memory
9. 32-input/output pins arranged as four 8-bit ports P0 – P3.
10. Two 16-bit timer/counters T0 and T1.
11. Full duplex serial data receiver.
12. Control register-TCON, TMOD, SCON, PCON, IP and IE.
13. Two external and three internal interrupt sources.
14. Oscillator and clock circuits.
Q.4.(b) (ii) Solution:

Displacement sensors are used to measure the amount by which some object has been
moved. In continous processes, the displacement sensors are used to measure the
thickness of a sheet, the diameter of a rod, the separation of rollers or some other dimension
of the product. The various sensor used for displacement measurement are
(i) potentiometer
(ii) resistance strain gauge
(iii) linear variable differential transformers (LVDT)
(iv) Push-pull displacement sensor
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Position sensors:
(i) photoelectric sensors
(ii) hall effect sensors
(iii) optical encoders
Applications of hall effect sensor
(i) it is used as a magnetic switch for electric transducer
(ii) it is used for the measurement of the position, displacement and proximity
(iii) It is used for measurement of current
(iv) It is used for measurement of power
Actuator
Control
valve
Intake Compressor Cooler Separator Receiver

filter
air
Secondary air
treatment
Pressure
switch
Motor control
center
a) Air filters: These are used to filter out the contaminants from the air.
b) Compressor: Compressed air is generated by using air compressors. Air
compressors are either diesel or electrically operated. Based on the requirement
of compressed air, suitable capacity compressors may be used.
c) Air cooler: During compression operation, air temperature increases. Therefore
coolers are used to reduce the temperature of the compressed air.
d) Dryer: The water vapor or moisture in the air is separated from the air by using a
dryer.
e) Control Valves: Control valves are used to regulate, control and monitor for
control of direction flow, pressure etc.
f) Air Actuator: Air cylinders and motors are used to obtain the required movements
of mechanical elements of pneumatic system.
g) Electric Motor: Transforms electrical energy into mechanical energy. It is used to
drive the compressor.
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h) Receiver tank: The compressed air coming from the compressor is stored in the
air receiver.
Q.4.(c) (ii) Solution:

When an instrument consists of different elements connected in series and having static
sensitivities k1, k2, k3 .... the overall sensitivity is expressed as follows:
q1 q q
k1 = ; k2 = 2 ; k3 = 0
qi q1 q2
q0 q1 q 2 q0
Overall sensitivity, k = = × × = k1 k 2 k3
qi qi q1 q2
k1 k2 k3 k1 k2 k3
k1 = Transducer sensitivity = 0.3 Ω/°C

k2 = Wheatstone bridge sensitivity = 0.01 V/Ω
k3 = Amplifier gain = 80 V/V
k4 = Pen recorder = 1.2 mm/V
Overall sensitivity, k = k1 × k2 × k3 × k4
= 0.3 × 0.01 × 80 × 1.2 = 0.288 mm/°C
⎡ ohm V V mm ⎤
⎢⎣ °C ohm V × V ⎥⎦
× ×
Change of output signal

Static sensitivity, k =
Change of input signal
30
0.288 =
Change of input signal
30
Temperature change = = 104.167°C Answer
0.288
Section B : IC Engine, Renewable Sources of Energy-2 + Industrial and
Maintenance Engineering -2
Q.5.(a) Solution:
The three basic requirements of a good S.I. engine combustion chamber are
1. Limit of compression ratio
2. Octane number.
3. Minimum air supplied.
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There is a limit for compression ratio in the case of S.I. engines. The range is between 6 to
10. It can extend to 12 in the case of race vehicles. Within this range the compression ratio
must be as high as possible for the combustion efficiency to be high.
If the compression ratio crosses the limit, then, the detonation will be frequent.
Besides, for higher power output the octane number for SI engines should be as high as
possible. Else detonation will be high. Example, in India, the Octane number for speed
and extra premium petrol is between 90 to 92. For normal petrol, it is between 70 to 80
(Octane number), detonation will be severe if octane number is below 60.
The minimum excess air supplied to SI engines is 10%. Sometimes, it is even 25 to 50%.
(Problems in chemical analysis). There are various reasons for excess air supplied. They
are
(a) lesser formation of Nox.
(b) better combustion of fuel.
(c) temperature will not be high enough to cause knocking.
(d) formation of Co (toxic) will be reduced.
Q.5.(b) Solution:
P
3
QS
2
4
QR
1
Maximum temperature, T3 = 1450°C = 1450 + 273 = 1723 K

Minimum temperature, T1 = 22°C = 22 + 273 = 295 K
Heat supplied, Qs = 900 kJ
Qs = Cv(T3 – T2)
Qs
T 2 = T3 − C
v
900
T 2 = 1723 − = 467.77 K
0.718
for process 1 → 2, T1V1γ–1 = T2 V2γ –1
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1 1
V1 ⎛ T2 ⎞ γ− 1 ⎛ 467.77 ⎞ 0.4
= ⎜T ⎟ =⎜ ⎟ = 3.166
V2 ⎝ 295 ⎠
⎝ 1⎠
V1
Compression ratio, r = V = 3.166 Answer
2
1 1
Cycle efficiency, η = 1 − γ−1 = 1 − = 0.36934 or 36.93%
n ( 3.166 )0.4
P3 P2
for process 2 → 3, T = T
3 2
γ
T T ⎛ T ⎞ γ− 1
P 3 = 3 P2 = 3 × P1 ⎜ 2 ⎟
T2 T2 ⎝ T1 ⎠
P3 1.4/0.4
1723 ⎛ 467.77 ⎞
×
P1 = 467.77 ⎝⎜ 295 ⎠⎟ = 18.4922 Answer
Q.5.(c) Solution:
Given: T = 25°C = 273 + 25 = 298 K
Enthalpy, ΔH°298k = – 296838 kJ/kg mole
Free energy, ΔG°298k = – 238291 kJ/kg mole
Efficiency of fuel cell, ηFC:
−ΔG° −238291
ηFC = =
−ΔH ° −296838
= 0.80276 or 80.276% Ans. (i)
Electrical work output per mole of H2O produced is given as
ΔGmax
Prev = Molar mass of hydrogen
238291
= × 10 −3 kW = 118.2 kW Ans. (ii)
2.016
Heat transfer to the surroundings, Q:
Q = TΔS = (ΔH°)298 K – (ΔG°)298 K
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= – 296838 + 238291
= – 58547 kJ/kg mole Ans. (iii)
The –ve sign indicates that heat is transferred from the system to surroundings.
Q.5.(d) Solution:
(I) Vapour lock is a situation where too lean a mixture is supplied to the engine. The
automotive fuel pump should handle both liquids and vapours. If the amount of
fuel evaporated in the fuel system is very high the fuel pump will mainly pump
vapour and very little liquid will go to the engine. This results in very weak mixture
which can’t maintain engine output. High rate of vaporization of gasoline can upset
the carburettor metering or even stop the fuel flow to the engine by setting up a
vapour lock in the fuel passages. This characteristics demand the presence of relatively
high boiling temperature hydrocarbons throughout the distillation range.
Vapour lock causes the following:
1. Uneven running of an engine.
2. Stalling while idling.
3. Irregular acceleration
4. Difficult to start when engine is hot
5. Momentary stalling while running
(II) Crankcase dilution: If very frequent starting of the engine with low engine temperature
is necessary, very rich mixtures have to be supplied and some of un-evaporated fuel
leaks past the piston rings and goes to crankcase. Consequently lubricating oil gas
gets diluted. This dilution decreases the viscosity of the lubricating oil and also washes
away the lubricating oil film on engine cylinder walls. It is found that the tendency of
fuels to dilute the lubricating oil lies in the range of 90% ASTM temperature. Thus
control of 90% ASTM temperature combined with proper ventilation of crankcase
reduces the dilution of crank case oil. In the engines using heavier fuels like kerosene
and other distrillates, the problem of dilution and poor lubrication of pistons and
rings may be severe.
Q.5.(e) Solution:
Number of cylinder, n = 4
Orifice diameter, d = 5 cm = 0.05 m
Coefficient of discharge, Cd = 0.6
Bore, D = 12 cm = 0.12 m
Stroke, L = 15 cm = 0.15 m
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N = 1200 rpm, hw = 5 cm of water
P 1 = 1 bar, T1 = 17°C = 273 + 17 = 290 K
P 1 × 10 5
Air density ρa = = = 1.2015 kg/m3
RT 287 × 290
Head causing flow (in meter of air):
hwρw 0.05 × 1000

ha = = = 41.615 m
ρa 1.2015
Air velocity, V = 2 gha = 19.62 × 41.615 = 28.574 m/s
Vactual = Cd × area × velocity (rate of flow)
π 2
= 0.6 × × 0.05 × 28.574 = 0.03366 m3/s
4
π 2
Swept volume, Vs = n × × D L × ( no.of cycles/sec )
4
π 2 1200
Vs = 4 × × 0.12 × 0.15 ×
4 60 × 2
Vs = 0.06786 m3/s
Vactual 0.03366
Volumetric efficiency, ηv = V =
swept 0.06786 = 0.496
η v = 0.496 or 49.6 % Answer
Q.6.(a) Solution:
Initial pressure, P1 = 1 bar
Initial temperature, T1 = 90 + 273 = 363 K
Compression ratio, r = 8
Maximum pressure, P3 = P4 = 68 bar
Total heat supplied, Qs = 1900 kJ/kg of air
For the isentropic process 1 – 2:
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P (bar)
3 4
68
adiabatic process
2
1 1 (90°C)
v (m3)
p 1V 1 γ = p 2V 2 γ
γ
⎛ V1 ⎞
P 2 = P1 ⎜ ⎟ = 1 × (8)1.4 = 18.38 bar Answer
⎝ V2 ⎠
γ− 1
T2 ⎛ V1 ⎞
Also, T1 = ⎜V ⎟
⎝ 2 ⎠
T 2 = T1 × (8)0.4 = 363 × 80.4 = 833.955 K Answer

P 3 = P4 = 68 bar Answer
For the constant volume process 2 – 3 :
P2 P3
T2 = T3
P3
T 3 = T2 × P
2
68
= 833.955 × = 3085.36 K Answer
18.38
heat added at constant volume :
Qsv = Cv(T3 – T2) = 0.717 (3085.36 – 833.955)
Qsv = 1614.26 kJ/kg
heat added at constant pressure = total heat added – heat added at constant volume
Qsp = Qs – Qsv
= 1900 – 1614.26 = 285.743 kJ/kg
Qsp = Cp(T4 – T3 ) = 285.743
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285.743
T4 = + 3085.36 = 3369.7 K Answer
1.005
for constant pressure process 3 – 4:
V4 T4 3369.7
ρ = V = T = 3085.36 = 1.09216
3 3
for adiabatic (or isentropic process) 4 – 5:
V5 V5 V2 V1 V3 r ⎛ V4 ⎞
V4 = × = × =
V2 V4 V2 V4 ρ ⎜ρ = V ⎟
⎝ 3⎠
γ γ 1.4
⎛ V4 ⎞ ⎛ρ⎞ ⎛ 1.09216 ⎞
P 5 = P4 ⎜ ⎟ = 68 × ⎜ ⎟ = 68 ⎜ ⎟
⎝ V5 ⎠ ⎝r⎠ ⎝ 8 ⎠
P 5 = 4.186 bar Answer
γ− 1 r −1 (1.4 − 1)
T5 ⎛ V4 ⎞ ⎛ρ⎞ ⎛ 1.09216 ⎞
Also, = ⎜ ⎟ =⎜ ⎟ =⎜ ⎟ = 0.4509
T4 ⎝ V5 ⎠ ⎝r⎠ ⎝ 8 ⎠
T 5 = 3369.7 × 0.4509 = 1519.4 K Answer
Work done Qs − Qr
Air standard efficiency; ηair-std = Heat supplied = Q
s
Heat rejected during constant volume process 5 – 1,

QR = Cv(T5 – T1)
= 0.717(1519.4 – 363) = 829.14 kJ/kg
1900 − 829.14
ηair–std = = 0.5636 or 56.36 % Answer
1900
Mean effective pressure is given by
Work done per cycle
Pm =
Stroke volume
1 ⎡ P4V4 − P5V5 P2V2 − P1V1 ⎤
=
Vs ⎢ P3 (V4 − V3 ) + γ−1
−
γ−1 ⎥
⎣ ⎦
V 1 = V5 = rVc , V2 = V3 = Vc , V4 = ρVc
Vs + Vc
r = Vc or Vs = (r – 1)Vc
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1 ⎡ ρ× P4Vc − P5 × rVc P2Vc − P1 × rVc ⎤

Pm =
(r − 1)Vc ⎢ P3 (ρVc − Vc ) + γ−1
−
γ−1 ⎥
⎣ ⎦
We have, r = 8, ρ = 1.09216, γ = 1.4, P1 = 1 bar, P2 = 18.38 bar,
P 3 = P4 = 68 bar, P5 = 4.186 bar
1 ⎡ ρP − rP5 P2 − P1r ⎤
Pm = ( ⎢ P3 (ρ − 1 ) + 4 −
r − 1) ⎣ r −1 r − 1 ⎥⎦
1 ⎡ 1.09216 × 68 − 8 × 4.186 18.38 − 1 × 8 ⎤
= ( ⎢ 68 (1.09216 − 1 ) + − ⎥⎦
8 − 1) ⎣ 0.4 0.4
1
= [6.26688 + 101.9472 − 25.95]
7
Pm = 11.752 bar Answer
Q.6.(b) (i)Solution:
Thermal efficiency is given by
1 ⎡⎣ ρ γ − 1 ⎤⎦
η = 1−
(rc )γ − 1 γ (ρ − 1 )
V1
where rc = compression ratio = V
2
V3
ρ = cut-off ratio = V
2
P
2 3
cp
Specific heat ratio, γ =
cv
c v = 0.717 kJ/kgK
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c p = γcV = 1.4 × 0.717 = 1.0038 kJ/kgK
V3 – V2 = 0.12(V1 – V2)
⎛ V3 ⎞ ⎛ V1 ⎞
⎜ V − 1 ⎟ = 0.12 ⎜ V − 1 ⎟
⎝ 2 ⎠ ⎝ 2 ⎠
(ρ – 1) = 0.12(16 – 1)
ρ – 1 = 1.8 or ρ = 2.8
⎡ ( 2.8 )1.4 − 1 ⎤
1
(η1)Diesel = 1− ⎢ ⎥ = 0.5776
(16 )0.4 ⎣ 1.4 ( 2.8 − 1 ) ⎦
Case II: When cv increases by 2%.
c v ′ = 1.02 × 0.717 = 0.73134 kJ/kgK
c p′ – c v′ = c p – c v = R
c p ′ = cp – cv + cv′
= 1.0038 – 0.717 + 0.73134 = 1.01814 kJ/kgK
c p′ 1.01814
γ′ = = = 1.3921
c v′ 0.73134
1 ⎡⎣ 2.81.3921 − 1 ⎤⎦
(η II)diesel = 1− = 0.5776
( 16 )0.3921 (1.3921 )( 2.8 − 1 )
1 3.187
= 1− × = 0.5704
2.955 1.3908 × 1.8
% change in efficiency of diesel cycle :
⎛ 0.5692 − 0.5704 ⎞
100 × ⎜ ⎟ = – 1.2465% Answer
⎝ 0.5776 ⎠
There is decrease in efficiency.

The possible causes of the observed differences between the actual cycle and the fuel-air
cycle include the following losses that are taken into account for the analysis of the actual
cycle: and which are not considered in the analysis of the fuel-air cycle.
1. Leakage
2. Imperfect mixing of fuel and air
3. Progressive burning
4. Burning time losses, due to the motion of the piston during combustion.
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5. Heat losses to the cylinder walls

6. Exhaust blowdown loss
7. Fluid friction
8. Gas exchange or pumping loss
2 πNT 2 πNWR WN ( 2 πR )
Brake power, BP = = =
60000 60000 60000
40 × 9.81 × 1500 × 3
= = 29.43 kW
60000
BP
ηbth = × 100
m f × CV
29.43 × 60
= × 100 = 20.066% Ans. (i)
0.2 × 44000
ηbth 20.066
ηith = × 100 = × 100 = 25.082% Ans.(ii)
ηm 80
bp 29.43
× 60000 × 60000
ηm 0.8
IMEP = =
LAnk π 1500
0.15 × × 0.12 2 × ×4
4 2
36.7875 × 60000
=
1.69646 × 10 −3 × 750 × 4
= 4.337 × 105 Pa = 4.337 bar Ans. (iii)
m f 0.2 × 60
BSFC = = = 0.40775 kg/kWh Ans. (iv)
BP 29.43
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Q.6.(c) (ii) Solution:
Family Molecular Saturated/unsaturated

General formula arrangement
(i) Paraffin Cn H2n + 2 Chain Saturated
(ii) Olefin Cn H2n Chain Unsaturated
(iii) Diolefin Cn H2n– 2 Chain Unsaturated
(iv) Naphthalene Cn H2n Ring Saturated
(v) Aromatic Cn H2n – 6 Ring Highly unsaturated
Q.7.(a)Solution:
It is a typical life cycle curve for most products. So basically, it is assumed that most
product follow a particular trend during their life cycle which relates their failure rate
with time. It goes as follows:
Decreasing Constant Increasing

failure rate failure rate failure rate
Observed failure
Failure rate
rate
Wear out
Early Constant (Random) failures
failure failures
Time
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Early failures Random failures Wearout

(Region 1) (Region 2) failures
e.g. faulty assembly, e.g. caused by (Region 3)
production failure, operational failure, e.g. fatigue failures,
wrong material, dirt particles, aging, pittings
maintenance failures
Failure rate λ(t)

clear design flaw
Lifetime t
Actions
practical trials, correct operation

pilot-run series, and maintenance, calculations,
production and correct use and practical trials
quality controlling application
Region 1 is characterized by a decreasing failure rate. The risk that a part will fail decreases
with increasing time. Such early failures are mainly caused by failures in the assembly,
production, material or by a definite design flaw.
The failure rate is almost constant in region 2. Thus, the failure risk remains the same.
Most of the time, this risk is also relatively low. Such failures are provoked for example
by operating or maintenance failures or by dirt particles. Normally, such failures are
difficult to pre-estimate. The failure rate increases rapidly in the region 3 for wear-out
failures. The risk that a part will fail increases rapidly with time. Wearout failures are
caused by fatigue failures, aging, pittings, etc.
• Preventive maintenance: Preventive maintenance is maintenance that is regularly
performed on a piece of equipment to lessen the likelihood of it failing.
Preventative maintenance is performed while the equipment is still working, so
that it does not break down unexpectedly.
Example: Scheduled maintenance. Replacing filters on an HVAC every 6 months.
• Breakdown maintenance: Breakdown maintenance is maintenance performed
on equipment that has broken down and is unusable. It is based on a breakdown
maintenance trigger. It may be either planned or it may be unplanned.
Example: Wait until your HVAC stops working and call a technician to come and
fix it.
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• Predictive maintenance: Predictive maintenance techniques are designed to help
determine the condition of in-service equipment in order to predict when
maintenance should be performed. This approach promises cost savings over
routine or time-based preventive maintenance, because tasks are performed only
when warranted.
Example: Having sensors installed in the HVAC machine to tell us operating
efficiency and expected efficiency to tell us when we need to replace filters.

Reliability is the probability that an item or system will not fail in a given time period,
and Availability is the probability that a component or system will be ready to use when
it is needed. Availability takes into account maintainability, repair time, spares
availability, lead time and other logistics considerations.
High reliability contributes to high availability, but it is possible to achieve a high
availability even with an unreliable product by minimizing repair time and ensuring
that spares are always available when they are needed. This is usually done with a simple
swap. When something fails, just swap it out with one on the shelf, and the system can
resume operation. The failed component can be then repaired while the system continues
to operate.
Definition of Reliability: The conditional probability, at a given confidence level, that
the equipment will perform its intended functions satisfactorily or without failure, i.e.,
within specified performance limits, at a given age, for a specified length of time, function
period, or mission time, when used in the manner and for the purpose intended while
operating under the specified application and operation environments with their
associated stress levels.
Definition of Availability: Availability is a measure of the degree to which an item is in
an operable state and can be committed at the start of a mission when the mission is
called for at an unknown (random) point of time. Availability as measured by the user is
a function of how often failures occur and corrective maintenance is required, how often
preventative maintenance is performed, how quickly indicated failures can be isolated
and repaired, how quickly preventive maintenance tasks can be performed, and how
long logistics support delays contribute to down time.

Reliability of three parallel units A, B and C is:
R 1 = [1 – (1 – RA)(1 – RB)(1 – RC)]
Reliability of two parallel units D and E is:
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R 2 = [1 – (1 – RD)(1 – RE )]
Reliability of two parallel units G and H is
R 3 = [1 – (1 – RG) (1 – RH)]
Therefore system reliability is the series system containing R1, R2, RF and R3, which is
Rs = R1 × R2 × RF × R3
Rs = [1 – (1 – RA)(1 – RB)(1 – RC)][1 – (1 – RD)(1 – RE)]RF[1 – (1 – RG)(1 – RH)]
Rs = [1 – 0.65 × 0.65 × 0.65][1 – 0.65 × 0.65] × 0.35 × [1 – 0.65 × 0.65]
Rs = 0.725375 × 0.5775 × 0.35 × 0.5775
Rs = 0.08467 or 8.467% Answer
Q.7.(c) Solution:
The following are main pollutants emitted by petrol engine:
(i) Hydrocarbons (HC)
(ii) Nitrogen oxides (NOx )
(iii) Carbon monoxide (CO)
(iv) Sulphur dioxide (SO2)
(v) Hazardous air pollutants
(vi) Greenhous gases
(vii) Lead emission
The main methods, among various methods, for SI engine emission control are:
1. Modification in the engine design and operating parameters.
2. Treatment of exhaust products of combustion.
3. Modification of the fuels.
1.Modification in the engine design and operating parameters:
1.1 Combustion chamber configuration:
Modification of combustion chamber involves avoiding flame quenching zones where
combustion might otherwise be incomplete and resulting in high HC emission.
Modification includes:
– Reduced surface to volume ratio
– Reduced squish area
– Reduced space around piston ring
– Reduced distance of the top piston ring from the top of the piston
1.2 Lower compression ratio:
– Lower compression ratio reduces the quenching effect by reducing the quenching
area, thus reducing HC.
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– Lower compression ratio also reduces NOx emissions due to lower maximum
temperature.
1.3 Modified induction system: In a multi-cylinder engine, it is always difficult to
supply designed A/F ratio under all conditions of load and power. This can be
achieved by proper design of induction system or using high velocity or multi-
choke carburettors.
1.4 Ignition timing: The ignition timing control is so adjusted as to provide normal
required spark advance during cruising and retard the same for idle running.
NO x emissions are reduced due to lowering of maximum combustion
temperatures. Also HC emission gets reduced due to high exhaust temperatures.
However, cooling requirements increase. The fuel economy also suffers to some
extent accompanied by some power loss.
1.5 Reduced valve operlap: Increased overlap allows some fresh charge to escape
directly and increase emission level. This can be controlled by reducing valve
overlap.
2. Treatment of exhaust products of combustion (Exhaust gas oxidation):
The exhaust gas coming out of exhaust manifold is treated to reduce HC and CO
emissions. Treatment of exhaust gas is done by using following devices:
– After burner
– Exhaust manifold reactor
– Catalytic converter
3. Exhaust emission control by fuel variation:
• The ability of a fuel to burn in mixture leaner than stoichiometric ratio is a rough
indication of its potential emission reducing characteristics and reduced fuel
combustion.
• If gasoline is changed to propane as engine fuel CO emission can substantially
be reduced with reduced HC and NOx ; and in changing from propane to methane
the CO as well as HC emission tough zero level and only the NOx remains as a
significant factor.
Other various methods are:
4. Blow-by control
5. Use of evaporation emission control device (EECD)
6. Control of oxides of nitrogen (NOx )
– By exhaust gas recirculation
– By use of catalyst
– By injecting water
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Q.8.(a) Solution:
Given: Uw = 20 m/s; D = 12 m; N = 45 rpm at ηmax
(i) Total power density in the wind stream:
p 1.0132 × 105
Air density, ρ = = = 1.205 kg/m3
RT 287(20 + 273)
∴ Gas constant, R = 287 J/kgK and patm = 1.0132 × 105 Pa

1 3
Total power, Ptotal = ρAbl (U w )us (us stands for up-stream)
2
Ptotal 1 3
∴ Total power density = A = 2 ρ (U w )us
bl
1 3
× 1.205 × ( 20 ) = 4820 W/m2
= Answer
2
(ii) Maximum obtainable power density:
8 3
Maximum power, Pmax = ρAbl (U w )us
27
Pmax 8 3
∴ Maximum power density = = ρ (U w )us
Abl 27
8
= × 1.205 × 20 3 = 2856.3 W/m2 Answer
27
(iii) Reasonably attainable power density:
16 16
η = ×
27 27
η = 0.3511 0.35
η = 35%, we get
P P 35
= η× total = × 4820 = 1687 W/m2 Answer
Abl Abl 100
(iv) Total power generated Ptotal
Ptotal = Power density × area
π 2 −3
= 1687 × D × 10 kW
4
π 2 −3
= 1687 × × ( 12 ) × 10 = 190.8 kW Answer
4
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(v) Torque at maximum efficiency, Tmax:
We know that, Pmax = Tmax × ω
2 πN
whre, ω (angular velocity) = rad/s
60
Pmax 60 ⎡ 8 π 3⎤
∴ Tmax = = ⎢ × 1.205 × × 12 2 × ( 20 ) ⎥
ω 2 πN ⎣ 27 4 ⎦
i.e. Tmax = 68551 Nm Answer
2 π× 45
12 ×
λ = 60 = 2.83
20
C P max 16 / 27
CT max = =
λ 2.83
CT max = 0.2096
(Tmax)actual = Tmax × CTmax
= 68551 × 0.2096
(Tmax)actual = 14367.4 Nm
Maximum axial thrust, Fx(max):
π 2
Fx (max) = ρD2 (U w )us
8
π 2 2
= × 1.205 × ( 12 ) × ( 20 ) = 27256 N Answer
8
1440
Gas is produced uniformly for 24 hours, gas-production rate = = 60 l/h
24
1440
Gas is consumed uniformly in 6 hours, gas-consumption rate = = 240 l/h
6
Gas holder size required to supply gas for 2 hours during which the production is also
continuing VG(1) = (240 – 60) × 2 = 360 litre.
Considering 25% factor of safety.
Gas holder size = 360 × 1.25 = 450 litre
The largest period of gas accumulation without its consumption is from 21 : 00 to 06 : 00
hours (i.e. 9 hours), the necessary gas-holder size would be
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VG(2) = 60 × 9 = 540 litre

So, VG(2) is the maximum relevant gas-holder size required.
With a safety margin of 25%, the required gas-holder size = 1.25 × 540 = 675 litre
So, the gas holder size required = 675 litre Answer
675
The required gas holder capacity = = 0.46875 = 46.875% Answer
1440
Type of rotor for horizontal axis wind turbine (HAWT)
Depending on the number of blades, wind speed and nature of application, rotors have
been developed in various types of shapes and sizes. Some of them are as follows:
Single blade, two blade and three blade rotor:
Driving force: Lift force
Single blade rotor is economical but produces noise and unbalance forces (ast it uses
counter balance weight).
In one blade and two blade rotor, teetering of rotor is required. As wind speed increases
with height, the axial force on blade when it attains the upper position is significantly
higher as compared to that when it is a lower position. It cause cyclic (sinusoidal) load
on a rigid hub leading to fatigue. This is greatly relieved by providing a teeter hinge (a
pivot within the hub) that allows a see-saw motion to take place out to the plane of
rotation (i.e. vertical plane).
Increasing the number blade from two to three: Use of teetering is not required. Cost
increases. Increasing three to four blade increase in efficiency is quiet low (around 0.5%)
but increase in cost is quiet high.
Application S. No. Driving force
Power generation I. Sail-wing rotor Lift force
Power generation or water pumping ii. Multi-bladed rotor Drag type
Water pumping iii. Dutch-type rotor Drag force
Water pumping
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Counter balance
weight
(a) Single-blade (b) Two- blade (c) Three- blade (d) Sailwing rotor
rotor rotor rotor
(e) Chalk multibladed (f) Americal multibladed

rotor rotor (g) Dutch-type rotor
Figure: Various types of rotors for HAWT
Q.8.(c) Solution:
Wind power law profile:
α
V1 ⎛ z1 ⎞
= ⎜ ⎟ ...(i)
V2 ⎝ z2 ⎠
where V 1 = wind velocity at some reference height z1
V 2 = wind velocity at height z2; and
α = Hellman exponent
The constant Hellman exponent (α) depends on the nature of the surface, stability of the
air, temperature, time of the day, season and surface roughness. It can be obtained as
α = 0.096[ln(Z0)] + 0.016[ln(Z0)]2 + 0.24
If detailed information about the flow does not exist, then for stable flow, a generally
accepted value for a (Hellman exponent) is 1/7 or 0.143.
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Sl. No. 10 m (x) 50 m (y) xy x2 y2

1 6 7.4 44.4 36 54.76
2 7.8 9.9 77.22 60.84 98.01
3 5.2 6.6 34.32 27.04 43.56
4 6.1 7.8 47.58 37.21 60.84
5 8.2 10.3 84.46 67.24 106.09
6 9.1 11.3 102.83 82.81 127.69
7 9.8 12.5 122.5 96.04 156.25
8 5.8 7.2 41.76 33.64 51.84
2 2
n=8 Σx = 58 Σy = 73 Σxy = 555.07 Σx = 440.8 Σy = 699.04
The linear regression equation has the form y = a + bx

(Σy )(Σx 2 ) − (Σx )(Σxy )
a =
n(Σx 2 ) − (Σx )2
73 × 440.8 − 58 × 555.07 15.66
= =− = – 0.08735
2 162.4
8 × 440.8 − (58)
nΣxy − (Σx )(Σy )
b =
n ( Σx 2 ) − ( Σx )
2
8 × 555.07 − 58 × 73 206.56
= =
8 × 440.8 − (58) 2 162.4 = 1.27087
Hence y = – 0.08735 + 1.2707 x 1.2707x
This equation is equivalent to V50 = δV10 where δ is the slope. So, the slope is 1.272.
Therefore, from equation (i):
a
V50 ⎛ 50 ⎞
δ = = ⎜ ⎟ = 5a
V10 ⎝ 10 ⎠
Taking natural logarithm of both sides:
l n( δ ) l n(1.272)
a = = = 0.1495
ln(5) l n(5)
As can be seen, the value is very near to the general value of 0.143. To obtain the data
for the 150 m height, we use
0.1495
⎛ 150 ⎞
V 150 = V50 ⎜ ⎟ = 7.4 × 30.1495 = 8.72 m/s
⎝ 50 ⎠
The complete set of results is shown in following table:
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Results for wind speed (m/s) at 150 m
50 m 150 m
7.4 8.72
9.9 11.667
6.6 7.778
7.8 9.1923
10.3 12.14
11.3 13.317
12.5 14.73
7.2 8.485

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ESE-2018 Mains Test Series: Mechanical Engineering Test No: 8

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ESE-2018 Mains Test Series: Mechanical Engineering Test No: 8

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ESE-2018 Mechanical Engineering

Figure: Block diagram of a microcomputer

The microprocessor consists of the following three segments:

= 0.77 × 0.75 × 0.897 × 0.443 × 210 (Se′ = 210 N/mm2)

0.9 Sut = 0.9 × 550 = 495 N/mm2

From the energy equilibrium:

⎛ 2 × 15 × 600 × 200 × 103 ⎞

The velocity and acceleration can be expressed by

θ (t ) = 2a3 + 6a4t

In the given problem, θi = 0°, θf = 60°, time, t = 5 seconds

Q.2 (a) Solution:

350 350 350

At C, Mb = 1465800 N-mm; Mt = 497359.1972 N-mm

Step 4: Shaft diameter

Q.2 (b) Solution:

The standard diameter of rivet hole (d) is 29 mm.

45 75 75 75 45 45 75 75 75 45 (All dimensions in mm)

4. Thickness of butt straps

Shearing resistance of all the 10 rivets,

S t rength of the joint 577800

Bending moment, M = Pe = 30 × 103 × 600 = 18 × 106 Nmm

Step II: Power transmitted by the clutch

μmrg rd z (ω22 − ω12 )

0.28 ( 2 )( 112 ) (145) ( 4 ) ( 151.8432 − 57.8652 )

2 πn2 Mt 2 π ( 1450 )(716935.92 )

The planar manipulator and its home configuration

Using trigonometry to derive the kinematic equations

General motion (x, y) will be given by

⎛x⎞ ⎛ cos (θ1 + θ2 + θ3 ) − sin (θ1 + θ2 + θ3 ) kx ⎞ ⎛ l1 + l2 + l3 ⎞

⎛π⎞ ⎛π⎞ ⎛π⎞

⎛π⎞ ⎛π⎞ ⎛π⎞

⎛π⎞ ⎛ 11π ⎞ ⎛ 13π ⎞

= 2cos90° + 2cos330° + cos390°

SF1 Spring force due to

NOTE : following laplace transform formula has been used :

Q.3.(c) (i) Solution:

(i) Accuracy as a “percentage of full scale reading”.

Step 2 : Combine two blocks in series:

Step 3 : Closed loop transfer function (CLTF)

Q.4.(a) (i) Solution:

mass = cross section area × perimeter × density

Q.4.(a) (ii) Solution:

⎛ ( 420 − 180 )2 + ( 180 − 0 )2 + ( 0 − 420 )2 ⎞

⎧ 420 − 180 180 − 0 420 − 0 ⎫

(ii) σ 1 = 0, σ2 = – 180 MPa, σ3 = – 420 MPa

(0 + 180 )2 + ( 420 − 180 )2 + (0 + 420 )2

Q.4.(b) (ii) Solution:

Q.4.(c) (i) Solution:

Intake Compressor Cooler Separator Receiver

Q.4.(c) (ii) Solution:

k1 = Transducer sensitivity = 0.3 Ω/°C

Change of output signal

Maximum temperature, T3 = 1450°C = 1450 + 273 = 1723 K

Head causing flow (in meter of air):

hwρw 0.05 × 1000

Air velocity, V = 2 gha = 19.62 × 41.615 = 28.574 m/s

Vactual = Cd × area × velocity (rate of flow)

η v = 0.496 or 49.6 % Answer

T 2 = T1 × (8)0.4 = 363 × 80.4 = 833.955 K Answer

T 5 = 3369.7 × 0.4509 = 1519.4 K Answer

Heat rejected during constant volume process 5 – 1,

1 ⎡ ρ× P4Vc − P5 × rVc P2Vc − P1 × rVc ⎤