ME - R S E, Ind. Maintenance Engg. Prod. Engg. Mat. Sci.-1 SOMMech-2 - SOL - 2551

Detailed Solutions
ESE-2018 Mechanical Engineering

Mains Test Series Test No : 6
Section A : Renewable Source of Energy, Industrial and Maintenance Engineering
Q.1.(a) Solution:
Sun’s N
ray
Normal to horizontal surface
θi
α
W E
horizontal surface
γs
from figure is clear that:

α + θi = 90°
⇒ α = 90 – θi
So, sinα = sin(90 – θi )
⇒ sinα = cosθi
⇒ sinα = cosφ cosδ cosω + sinδ sinφ ...(1)
Given that:
φ = 40°N
η(No. of days of year starting from 1st January.)
Test No : 6 MECHANICAL ENGINEERING | 9
η(16 June) = 31 + 28 + 31 + 30 + 31 + 16
η = 167
Declination angle(δ) can be calculated by Cooper’s relation:
⎡ 360
δ = 23.45sin ⎢ ( 284 + η)⎤⎥
⎣ 365 ⎦
⎡ 360
= 23.45 sin ⎢ ( 284 + 167 )⎤⎥
⎣ 365 ⎦
δ = 23.35°
ω(hour angle) = [solar time – 12:00] (in hours) × 15°/hour
solar time = 12 : 00 + 2 = 14 : 00 hours
ω = (14: 00 – 12 : 00)(in hours) × 15°/hour
ω = 30°
Substituting value of φ, δ and ω in equation (1),
sinα = cos40° cos23.35° cos30° + sin 40° sin23.35°
sinα = 0.864
⇒ α = 59.75° Answer
Day length/On June 16[td]:
2 ωb 2
td = = cos −1 [− tan φ tan δ ]
15 15
2
td = cos −1 [− tan 40° tan 23.35°]
15
td = 14.83 hours Answer
Sunrise and Sunset:
td is total duration of sunshine from sunrise to sunset. Time taken from sunrise to solar
noon (i.e. 12 : 00 L.A.T) and time taken from solar noon to, sunset is same.
td
So, solar time = 12 : 00 − = 12 : 00 – 07 : 24
2
= 04 : 36 hour Answer
td
And solar time at sunset = 12 : 00 + = 12 : 00 + 07 : 24
2
= 19 : 24 hour Answer
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10 | ESE 2018 : MAINS TEST SERIES
Q.1.(b) Solution:
Break power of engine = 200 kW
80% diesel replacement, now 80% power will be produced by biomass (producer gas).
Power by biomass = 0.8 × total brake power
= 0.8 × 200 = 160 kW
Actual total power of biomass used,
Power by biomass
Heat supplied = ηgasifier ×ηengine
160
= = 609.5238 kW
0.75 × 0.35
Heat supplied
Mass flow rate of biomass required =
Calorific value of fuel
609.5238 609.5238 × 3600

= = = 129.0756 kg/h Answer
17000 17000
Q.1.(c) Solution:
ABC analyis is an analysis of a range of objects, such as finished products, items lying in
inventory or customers into three categories. It is a system of categorization, with
similarities to Pareto analysis, and the method usually categorized inventory into three
classes with each class having a different management control. Rating of items from A to
C are done as follows:
A– Items: 10 – 20% of the items account for 70–80% of the usage value.
B – Items: 15 – 25% of the items account for 10–20% of the usage value.
C – Items: 65 – 75% of the items account for 5–10% of the usage value.
‘A’ class items are closely monitored because of the value involved (70 – 80%).
Cumulative percentage
of total cost
B C
A
0 100
Cumulative percentage of total items
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Q.1.(d) Solution:
Different techniques for the condition monitoring are
1. Visual inspection
2. Vibration based analysis
3. Acoustics based analysis
4. Wear debris analysis
5. Performance analysis and
6. Thermography and other NDT techniques
Main objectives for the condition monitoring can be listed as
1. Prediction of faults.
2. Diagnosis of faults.
3. More safety at work place.
4. Less down time leading to more production and
5. Better inventory management for the spare parts.
Q.1.(e) Solution:
1. Zero wear: Removal of material which causes polishing of material surfaces may
be known as “zero wear”. It may increase performance. It is for betterment, so it
is not undesirable.
2. Measurable wear: Removal of material from surface that increases vibration; noise
or surface roughness may be treated as “Measurable wear”. Often we measure
wear in volume or mass reduction. Undesirable removal of material occurs in
measurable wear.
Measurable wear refers to a loss of material which must be counted to estimate
the life of turbo-pair. The extent of measurable wear depends on the lubrication
regime, the nature of the load, the surface hardness and roughness, and on the
contaminates in the lubricating oil. A typical example of measurable wear in
helical gear is typically known as pitting wear.
Wear Mechanisms: Wear can be classified based on the ways that the frictional
junctions are broken, i.e., elastic displacement, plastic displacement, cutting,
destruction of surface films and destruction of bulk material. There are many
types of wear mechanisms, but common wear mechanisms are:
• Abrasive wear: polishing, scouring, scratching, grinding, gouging.
• Adhesive wear : galling, scuffing, scoring.
• Cavitation (interaction with fluid).
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• Corrosive wear (chemical nature).

• Erosive wear.
• Fatigue: delaminaiton.
• Fretting wear.
Q.2.(a) Solution:
Numerical part: Uw = 18 m/s, Uw = 0.33 Uw = 5.94 m/s
1 2 1
Uw = 0.6 Uw = 10.8 m/s
,b 1
P1
ρa = = 1.175 kg/m3
RT
⎡ 2
1 1 ⎛U ⎞ ⎤
ρ A ⎡U 12 − U w 22 ⎤⎦ ρ A ⎢U 1 − ⎜
2 w 1 ⎟ ⎥
Fx(max) 2 a b⎣ w 2 a b ⎢⎣ w ⎝ 3 ⎠ ⎥⎦
= =
Fmax 1 2 1
ρa AbU w 1 ρa AbU w 12
2 2
Fx (max )
= 0.889 Answer
Fmax
Derivation:
Upstream
u0 u1 u2
P0, ρ0 Downstream
P2, ρ2
A1
A2
Turbine
Figure: Wind stream tube in pressure of turbine
= ρA0u0 = ρA1u1 = ρA2u2

m
where u0 = wind speed upstream
u2 = wind speed downstream
Thrust on the rotor, F = m u0 − m u2
( u0 − u2 ) u1
Power extracted by the turbine, PT = Fu1 = m ...(1)
Power extracted from wind is also equal to loss in kE per unit time.
Thus Pw =
1
2
(
m u02 − u22 ) ...(2)
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from eq. (1) and (2)
u0 + u2
⇒ u1 =
2
Now suppose we have an interference factor a, defined as fractional wind speed decrease
at the turbine
(u0 − u1 )
Thus a =
u0
⇒ u1 = (1 – a) × u0
u1 ⎛ u + u2 ⎞ u0 − u2
a = 1− = 1−⎜ 0 ⎟ = 2u
u0 ⎝ 2 u0 ⎠ 0
and u2 = (1 – 2a)u0
thus extracted turbine power is
1 2
PT = × A1 × ρ× ( 2 au0 ) ⎡⎣ u0 + ( 1 − 2 a ) u0 ⎦⎤
4
1 2
= × A1ρa u0 × u02 × 4 ( 1 − a )
2
= 2 × A1ρ × a(1 – a)2 × u03
2 ⎡1 3⎤
= 4 a ( 1 − a ) ⎢ ρA1u0 ⎥
⎣2 ⎦
But wind power available for given area A1
1
P0 = ρA1u03
2
PT = 4a(1 – a)2 P0 = Cp × P0
where Cp is the power coefficient and
C p = 4a (1 – a)2
for Cp to be maximum
dCp
= 0
da
= 4(1 – a)2 – 8a(1 – a)
= 4(1 – a)(1 – a – 2a)
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= 4(1 – a)(1 – 3a)

a = 1, 1/3
at a = 1, cp = 0, so neglected.
1
∴ at a = , c is maximum.
3 p
2
1⎛ 1⎞
and (Cp)max = 4× ⎜1− ⎟
3⎝ 3⎠
16
(Cp)max = = 0.593
27
0.593
0.5
0.4
Cp 0.3
0.2
0.1
0.2 1/3 0.4 0.6 1
Q.2.(b) Solution:
A fuel cell is an electrochemical energy conversion device that continuously converts
chemical energy of a fuel directly into electrical energy. Continuous operation requires
supply of fuel and oxidant and removal of water vapor, spent fuel, spent oxidant, inert
residue and heat. It is known as a cell because of some similarities with a primary cell.
Like a conventional primary cell it also has two electrodes and an electrolyte between
them and produces AC power. It is also a static power conversion device. However,
active materials are generally supplied from outside unlike a conventional cell where it
is contained inside the cell. Fuel is supplied at the negative electrode, also known as
fuel electrode or anode and the oxidant is supplied at positive electrode, also known as
oxidant electrode or cathode. The only exhaust of a fuel cell, if pure hydrogen is used as
fuel (and pure oxygen as oxidant), is water vapour, which is not a pollutant. In case of a
hydrocarbon fuel, carbon dioxide is also produced. If air is used as oxidant, nitrogen
(spent air) is also produced in the exhaust. No other pollutant such as particulate matter,
NOx and SOx are produced. Some amount of heat is also produced. Some other pollutant
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also produced, which can be easily dissipated to the atmosphere or used locally for
heating purposes. No cooling water is required unlike conventional thermal power-
conversion devices where a substantial quantity of cooling water is required.
As the conversion of chemical energy of fuel to electrical energy occurs directly without
intermediate thermal stage, the efficiency of conversion is better and not limited by Carnot
efficiency of thermal stage. The efficiency of a practical fuel cell may be around 50%. The
average cell voltage is typically about 0.7 V (on rated load) and several cells may be
connected by series parallel connection of the required number of cells. A general large-
scale use will require the development of a low-cost fuel cell with a reasonably long life.
The main advantages of a fuel cell are: (i) it is quiet in operation as it is a static device, (ii)
it is less pollutant, (iii) its conversion efficiency is more due to direct single-stage energy
conversion, (iv) fuel cell plant can be installed near the point of use, thus transmission
and distribution losses are avoided, (v) no cooling water is needed as required in the
condenser of a conventional steam plant. The heat generated can be easily removed
and discharged to the atmosphere or used locally, (vi) because of modular nature, any
voltage/current level can be realized and the capacity can be added later on as the
demand grows, (vii) fuel-cell plants are compact and require less space, (viii) availability
to choose from large number of possible fuels, (ix) can be used efficiently at part load
from 50% to 100%, and no extra charging is required.
Classification of fuel cell:
(a) Based on the type of electrolyte
(i) Phosphoric acid fuel cell (PAFC)
(ii) Alkaline fuel cell (AFC)
(iii) Polymer electrolytic membranes fuel cell (PEMFC) or solid polymer fuel
(iv) Molten carbonate fuel cell (MCFC)
(v) Solid oxide fuel cell (SOFC)
(b) Based on the types of the fuel and oxidant
(i) Hydrogen (pure)– Oxygen (pure) fuel cell
(ii) Hydrogen rich gas– air fuel cell
(iii) Hydrazine–Oxygen/hydrogen peroxide fuel cell
(iv) Ammonia–air fuel cell
(v) Synthesis gas–air fuel cell
(vi) Hydrocarbon (gas)– air fuel cell
(vii) Hydrocarbon (liquid)–air fuel cell
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(c) Based on operating temperature

(i) Low temperature fuel cell (below 150°C)
(ii) Medium temperature fuel cell (150°C – 250°C)
(iii) High temperature fuel cell (250°C – 800°C)
(iv) Very high temperature fuel cell (800°C – 1100°C)
(d) Based on application
(i) Fuel cell for space applications
(ii) Fuel cell for vehicle propulsion
(iii) Fuel cell for submarines
(iv) Fuel cell for defense applications
(v) Fuel cell for commercial applications
(e) Based on the chemical nature of electrolyte
(i) Acidic electrolyte type
(ii) Alkaline electrolyte type
(iii) Neutral electrolyte type
Q.2.(c) Solution:
The following are the advantages of tidal power:
1. About two-third of earth’s surface is covered by water, there is scope to generate
tidal energy on large scale.
2. Techniques to predict the rise and fall of tides as they follow cyclic fashion and
prediction of energy availability is well established.
3. The life of tidal energy power plant is very long.
4. Tidal energy is a clean source of energy and does not require much land or other
resources as in harnessing energy from other sources.
5. It is an inexhaustible source of energy.
6. It is an environment friendly energy and does not produce greenhouse effects.
7. Despite the fact that capital investment of construction of tidal power is high,
running and maintenance costs are relatively low.
The following are the disadvantages of tidal power.
1. Capital investment for construction of tidal power plant is high.
2. Only a very few ideal locations for construction of plant are available and they
too are localized to coastal regions.
3. Unpredictable intensity of sea waves can cause damage to power generating units.
4. Aquatic life is influenced adversely and can disrupt the migration of fish.
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5. The energy generated is not much as high and low tides occur only twice a day
and continuous energy production is not possible.
6. The actual generation is for a short period of time. The tides only happen twice a day
so electricity can be produced only for that time, approximately for 12h and 25 min.
7. This technology is still not cost effective and more technological advancements
are required to make it commercially viable.
Difficulties in tidal power developments:
1. Usually the places where tidal energy is produced are far away from the places
where it is consumed. This transmission is expensive and difficult.
2. Intermittent supply: Cost and environmental problems, particularly barrage
systems are less attractive than some other forms of renewable energy.
3. Cost: Before jumping to conclusion that this renewable, clean resource is the
answer to all our problems, the disadvantages of using tidal and wave energy
must be considered. The main disadvantage is the cost of those plants.
4. Altering the ecosystem at the bay: Damages such as reduced fishing, winter icing,
and erosion can change the vegetation of the area and disrupt the balance. Similar
to other ocean energies, tidal energy has several prerequisites that make it only
available in a small number of regions.
T & S Turbine & sluice gate
High tide
level (h) S
E
Basin
T&S A
Low tide level (h0)
Figure: Single Basin tidal plant
Potential tidal power can be reckoned based on a mathematical calculation. Let us assume
that the surface area of the reservoir as stable between the full stored water level and the
emptied floor, the energy produced by the ebbing water can be expressed as
d(W) = ρghd(V) = ρgAh dh
Here d(W) = energy unit; ρ = density of seawater; g = acceleration due to gravity; A =
surface area of the reservoir assumed as a constant from high tide to low tide; h = instant
water level height (m); V = volume of reservoir, R = tidal range, h0 = minimum head
below which turbine cannot work.
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1. Total work done in filling or emptying the basin (h to h0)
W = ∫ dw = ∫ ρgAh dh
=
1
2
(
ρgA R 2 − h02 )
1
= × 1025 × 9.81 × 25 × 10 6 (10 2 − 2 2 )
2
W = 12.066 × 1012 Nm or J Answer
2. Average power,
W 12.066 × 1012
Paverage = = = 539.865 × 106 W Answer
t 22350
Also, average power of plant = ηg × Pavg =0.75 × 539.865
= 401.91 MW
[t = 6 hour and 12.5 min = 6 × 3600 + 60 × 12.5 = 22350 s]
3. Energy generated (in one filling)
0.75 × 539.865 × 106 × 3600

E = = 1.457 × 109 kWh
1000
Q.3.(a) Solution:
1
3 6
7 5 5
3 5
1 2 5 7
7
2 4
4
Different network paths are:

Path 1 – 2 – 5 – 7 = 15 days
Path 1 – 2 – 4 – 7 = 13 days
Path 1 – 3 – 5 – 7 = 17 days
Path 1 – 3 – 6 – 7 = 13 days
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t0 + 4tm + t p
Predecessor Event Successor Event tE =
6
(days)
5 + 4 × 6 + 13
1 2 =7
6
2 + 4 × 7 + 12
1 3 =7
6
1.5 + 4 × 2 + 2.5
2 4 =2
6
1+ 4× 3+ 5
2 5 =3
6
4+ 4×5+6
3 5 =5
6
1+ 4×1+1
3 6 =1
6
2 + 3 × 4 + 10
4 7 =4
6
4+5×4+6
5 7 =5
6
3+5×4+7
6 7 =5
6
Hence the path 1 – 3 – 5 – 7 is the critical path and the project duration is 17 days.
When duration of activity 3 – 5 is shortened to two days, we have to examine whether
the same path remains critical or any other path becomes critical.
Path 1 – 2 – 5 – 7 = 15 days ← New critical path
Path 1 – 3 – 5 – 7 = 14 days
Path 1 – 2 – 4 – 7 = 13 days
Path 1 – 3 – 6 – 7 = 13 days
Now path 1 – 2 – 5 – 7 is critical path and project duration is 15 days.
1
3 6
7 2 5
3 5
1 2 5 7
7
2 4
4
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Reduction in project duration = 17 – 15 = 2 days

So, on shortening the activity 3 – 5, we can reduce the project by 2 days only.
Gain by shortening of project duration = ` 5000 × 2 = ` 10000
Expenditure incurred to the company = ` 12500
Hence, the firm should not spend ` 12500 for shortening time of activity to 2 days.
Q.3.(b) Solution:
Monthly demand, D = 225 units
Carrying cost, CC = 2% of unit cost per month
Ordering cost, C0 = ` 100 per order
Step 1: Let us start with highest discount when C = ` 10.70.
2DC0 2 × 225 × 100

Q3* = =
CC 0.02 × 10.70 = 458.56 units
For availing discount Q > 700 but Q3* = 458.56 < 700, (not feasible) so we have to go to
next step.
2DC0 2 × 225 × 100

Step 2: Q2* = =
CC 0.02 × 11.2 = 448.21 units
Q2* = 448.21 < 550 < Q < 700, (not feasible)
2DC0 2 × 225 × 100

Step3: Q2* = =
CC 0.02 × 12 = 433 units
Calculation of total cost:

D Q *
TC(Q1*) = TC(at Q1* = 433) = DC1 + C0 + 1 CC
Q1 * 2
225 433
= 225 × 12 + × 100 + × 0.02 × 12
433 2
= 2700 + 51.963 + 51.96 = ` 2803.92
225 550
TC(550) = 225 × 11.2 + × 100 + × 0.02 × 11.2
550 2
= 2520 + 40.91 + 61.6 = ` 2622.51
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225 700
TC(Q* = 700) = 225 × 10.7 + × 100 + × 0.02 × 10.7
700 2
= 2407.5 + 32.143 + 74.9
= ` 2514.543 (minimum cost)
Hence optimal order quantity is at 700 units. Answer
Q.3.(c) (i) Solution:

Production planning and control (PPC) is one of the most important areas of industrial
management. It is aimed at achieving the efficient utilization of resources (material, men,
facility etc.) in any organization through planning, coordination and control of production
activities that transform the raw material into finished products. The PPC department
works with many industrial engineering techniques for issuing directives to the
production department for issues such as:
• What to produce ?
• How to produce?
• When to produce?
• What means (resources) are needed in production?
• How to coordinate different resources of the system?
• How to control the deviations from schedule?
Objectives of PPC:
1. It is used to establish target and check the deviations by comparing on some
performance measure.
2. Decides the nature and magnitude of different input factors to produce the output.
3. Elimination of bottleneck.
4. Smooth flow of material.
5. Utilization of inventory in the optimal way.
6. Coordinates different resources of production system in the most effective and
economic manner and to coordinate among different departments.
7. Forecasting of demand.
8. To produce in right quantity and quality at the right time.
9. Scheduling production activities to meet delivery schedule.
10. Expediting the system under production.
11. Quality management.
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Q.3.(c) (ii) Solution:
CPM PERT
(i) CPM uses activity network. PERT uses event oriented network
(ii) Useful for construction projects Useful for R & D projects
(iii) Based on deterministic model Based on probabilistic model
(iv) CPM can control both time and

PERT is basically a tool for planning
cost when planning
(v) Duration of activity may be estimated Time estimation not so accurate and
with a fair degree of accuracy definite.
Practical examples,
CPM : Construction work, IT development etc.
PERT: Real state development scheduling software etc.
Q.4.(a) Solution:
When a transducer is used in conjuction with another device to measure vibrations, it is
called a vibration pickup. The commonly used vibration pickups are known as seismic
instruments. A seismic instrument consists of a mass-spring-damper system mounted
on the vibrating body, as shown in figure (i). Then the vibratory motion is measured by
finding the displacement of the mass relative to the base on which it is mounted.
The instrument consists of a mass m, a spring k, and a damper c inside a cage, which is
fastened to the vibrating body. With this arrangement, the bottom ends of the spring and
the dashpot will have the same motion as the cage (which is to be measured, y) and their
vibration excites the suspended mass into motion. Then the displacement of the mass
relative to the cage, where x denotes the vertical displacement of the suspended mass,
can be measured if we attach a pointer to the mass and a scale to the cage, as shown in
figure (i). Then the vibratory motion is measured by finding the displacement of the
mass relative to the base on which it is mounted.
The vibrating body is assumed to have a harmonic motion:
y(t) = Ysinωt
The equation of motion of the mass m can be written as
mx + c( x − y ) + k( x − y ) = 0
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x(t)
k y(t)
c
T
Figure (i) Seismic instrument

By defining the relative displacement z as
z = x–y
Equation of motion can be re-written as
mz + cz + kz = −my
Above equation leads to
mz + cz + kz = mω2Y sin ωt
Steady state solution for this equation is given as :
z(t) = Zsin(ωt – φ)
where Z and φ are given by
mY ω2 r 2Y
Z = =
1/2 1/2
⎡⎣( k − mω2 ) + c 2 ω2 ⎤⎦
⎡ 2 2 2⎤
⎢⎣(1 − r ) + ( 2 ζr ) ⎥⎦
−1 ⎛ cω ⎞ ⎛ 2ζr ⎞
φ = tan ⎜ = tan −1 ⎜
2⎟ ⎟
⎝ k − mω ⎠ ⎝ 1 − r2 ⎠
c ω
ζ = 2 mω r= ω
n n
and
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4
ζ= 0
Z ζ = 0.25
Y
2
ζ = 0.50
1
ζ = 0.70
ζ = 1.00
0 1 2 3 4 5
ω
Range for ωn Range for
accelerometer vibrometer
Figure (ii): Response of a vibration measuring instrument

180°
ζ = 0.05
ζ = 0.25
ζ = 1.0
Phase angle, φ
120° ζ = 0.7
ζ= 1 ζ = 0.5
ζ = 0.7
60° ζ = 0.5
ζ = 0.25
ζ = 0.05
0 1 2 3
Frequency ratio, r
Figure (iii): Variation of phase angle vs. frequency ratio
Q.4.(b) (i)Solution:
Reliability engineering deals with the design and construction of systems and products,
taking into account the unreliability of their parts and components. It also includes testing
and programs to improve reliability. Good engineering results in a more reliable end
product.
Reliability science is concerned with the properties of materials and the causes for
deterioration leading to part and component failures. It also deals with the effect of
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manufacturing processes (for example, casting, annealing) on the reliability of the part of
component product.
Reliability management deals with the various management issues in the context of
managing the design, manufacture, and/or operation of reliable products and systems.
Here, the emphasis is on the business viewpoint, since unreliability has consequences in
terms of cost, time wasted and, in certain cases, the welfare of an individual or even the
security of a nation.
Q.4.(b) (ii)Solution:
C1 C2 C3 C4 C5
0.70
0.75
0.95 0.95 0.70 0.9
0.75
0.70
Inital reliability of system R(s) = R(C1) × R(C2) × R(C3) × R(C4) × R(C5)

= 0.95 × 0.95 × 0.7 × 0.75 × 0.9
R(s) = 0.42643 Answer
Systems reliability is very less
Now, when modified system is used
R′(s) = R(C1) × R(C2) × R(C3)′ × R(C4)′ × R(C5)
= 0.95 × 0.95 × (1 – 0.33) × (1 – 0.252) × 0.9
= 0.95 × 0.95 × 0.973 × 0.9375 × 0.9
= 0.7409243 Answer
R(C3)′ = 1 – (1 – R)(1 – R)(1 – R)
= 1 – (1 – 0.7)(1 – 0.7)(1 – 0.7) = 0.973
R(C4)′ = 1 – (1 – 0.75)(1 – 0.75) = 0.9375 Answer
Q.4.(c) Solution:
(i) Fault tree analysis (FTA) :
FTA is concerned with the identification and analysis of conditions and factors that cause,
or may potentially cause or contribute to the occurrence of a defined top event (such as
failure of a system). A fault tree is an organized graphical representation of the conditions
or other factors causing or contributing to the occurrence of the top event.
FTA can be used for analysis of systems with complex interactions between the
components, including software-hardware interactions. FTA is a deductive (top-down)
method of analysis aimed at pinpointing the causes or combinations of causes that can
lead to the defined top event. The analysis can be qualitative or quantitative, depending
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on the scope of the analysis. FTA may be undertaken independently, or in conjuction

with, other reliability analysis and its objectives includes:
• Identification of the causes or combinations of causes leading to the top event;
• Determination of whether a particular system reliability measure meets a stated
requirement;
• Determination of which potential failure mode(s) or factor(s) would be the highest
contributor to the system probability of failure(unreliability) or unavailability,
when a system is repairable, for identifying possible system reliability
improvements; and
• Analysis and comparison of various design alternatives to improve system
reliability.
(ii) Failure modes and effects analysis (FMEA):
FMEA is a structured, logical, and systematic approach. FMEA involves reviewing a
system in terms of its subsystems, assemblies, and so on, down to the component level,
to identify failure modes and causes and the effects of such failure on a system’s function.
The exercise of identifying component failure modes and determining their effects on
the system function assists the design engineer/analyst in developing a deeper
understanding of the relationship among the system components. The analyst can then
use this knowledge to suggest changes to the system that can eliminate or mitigate the
undesirable consequences of a failure. FMEA is used to access system safety and to
identify design modifications and corrective actions needed to mitigate the effects of a
failure on the system. The objectives of FMEA are as follows:
• To ensure that all conceivable failure modes and their effects on operational
success of the system have been considered.
• To list potential failures and identify the magnitude of their effect.
• To provide historical documentation for future reference to aid in the analysis of
field failure and consideration of design changes.
• To provide a basis for establishing corrective action priorities.
• To assist in the objective evaluation of design requirements related to redundancy,
failure detection systems, fail-safe characteristics, and automatic and manual
override.
Section B : Production Engineering & Material Science - 1, SOM & Mechanics - 2

Q.5 (a) Solution:
For sand casting, sand is the mould material, a two-piece mould is used, ordinarily the
surface finish is not an important consideration, the sand may be reused (but the mould
may not), casting rates are low, and large pieces are usually cast.
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For die casting, a permanent mould is used, casting rates are high, the molten metal is
forced into the mould under pressure, a two-piece mould is used, and small pieces are
normally cast.
For investment casting, a single-piece mould is used, which is not reusable; it results in
high dimensional accuracy, good reproduction of detail, and a fine surface finish; and
casting rates are low.
For lost foam casting, the pattern is polystyrene foam, whereas the mould material is
sand. Complex geometries and tight tolerances are possible. Casting rates are higher
than for investment, and there are few environmental wastes.
For continuous casting, at the conclusion of the extraction process, the molten metal is
cast into a continuous strand having either a rectangular or circular cross-section; these
shapes are desirable for subsequent secondary metal-forming operations. The chemical
composition and mechanical properties are relatively uniform throughout the cross-
section.
Q.5 (b) Solution:

Hybrid composites are those composites which have a combination of two or more
reinforcement fibres. The most common hybrid composites are carbon-aramid reinforced
epoxy (which combines strength and impact resistance) and glass-carbon reinforced epoxy
(which gives a strong material at economical rates). Hybrid composites are usually used
when a combination of properties of different types of fibres wants to be achieved, or
when longitudinal as well as lateral mechanical performances are required. The most
important criteria for the effective use of polymer composite materials are their life
durability, such as fatigue and long-time strength, crack propagation resistance, plasticity
reserve at long-term loading, resistance to impact loads, maintainability of articles and
there form, etc. The multifunctionality of the material is of prime importance: the
combination of high elastic strength properties with optimal thermophysical ones, radio-
engineering indices, resistance to combustion, low smoke emission, non-toxicity and
other specific characteristics. The diverse and contradictory requirements for modern
composite materials has brought to the forefront the very complex problem of developing
new types of composite materials, in which a combination of reinforcing layers from two
or more types of fibres with a common matrix are called hybrid composite materials.
Polymer hybrid composite materials (PHCM) have found the widest application to the
present time.
The term hybrid effect has been used to describe the phenomenon of an apparent
synergistic improvement in the properties of a composite containing two or more types
of fiber. The selection of the components that make up the hybrid composite is determined
by the purpose of hybridization, requirements imposed on the material or the construction
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being designed. The problem of selecting the type of compatible fibres and the level of
their properties is of prime importance when designing and producing hybrid composites.
The successful use of hybrid composites is determined by the chemical, mechanical and
physical stability of the fiber / matrix system.
Applications:
• Hybrid composite materials have extensive engineering application where strength
to weight ratio, low cost and ease of fabrication are required. Hybrid composites
provide combination of properties such as tensile modulus, compressive strength
and impact strength which cannot be realized in composite materials.
• To produce composites for lightweight structural applications.
• Helicopter rotor blades and drive shafts
• Floor panels of aircrafts
• In automobile sector they are used in transmission units, chassis members,
suspensions, and structural body parts of cars and lorries
• CFRP/ARP hybrids are used for making bicycle frames
• In sports industries Tennis racquets, fishing rods, skis, golf club shafts, yacht hulls,
hockey sticks and paddles
Q.5 (c) Solution:

Process Annealing: Process annealing is a heat treatment process that is used to negate
the effects of cold working that is to soften and increase the ductility of a previously
strain-hardened metal. It is commonly utilized during fabrication procedures that require
extensive plastic deformation, to allow a continuation of deformation without fracture
or excessive energy consumption. Recovery and recrystaligation processes are allowed
to occur, Ordinarily a fine-grained microstructure is desired, and therefore, the heat
treatment is terminated before appreciable grain growth has occurred. Surface oxidation
or scaling may be prevented or minimized by annealing at a relatively low temperature
(but above the recrystallization temperature) or in a nonoxidizing atmosohere.
Normalizing: Steels that have been plastically deformed for example in a rolling
operation, consist of grains of pearlite (and most likely a proeutectoid phase), which are
irregularly shaped and relatively large, but vary substantially in size. An annealing heat
treatment called normalizing is used to refine the grains (i.e. to decrease the average
grain size) and produce a more uniform and desirable size distribution fine-grained
steels are tougher than coarse-grained ones.
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1000 1800
1700
900 Normalizing
Acm
Temperature (°C)
Temperature (°F)
1600
Full annealing 1500

800 A3
1400
A1 1300
700
600 1200
0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

Composition (wt.%C)
Spheroidizing: Medium- and high-carbon steels having a microstructure containing even

coarse pearlite may still be too hard to conveniently machine or plastically deform. These
steels, and in fact any steel, may be heat treated or annealed to develop the spher-oidite
structure. Spheroidized steels have a maximum softness and ductility and are easily
machined or deformed. The spheroidizing heal treatment, during which there is a
coalescence of the Fe3C to form the spheroid particles.
• Heating to a temperature just above the eutectoid temperature, and then either cooling
very slowly in the furnace, or holding at a temperature just below the eutectoid
temperature.
• Heating and cooling alternately within about ±50°C of the A1 line of above figure
To some degree, the rate at which spheroidite forms depends on prior microstructure.
For example, it is slowest for pearlite, and the finer the pearlite, the more rapid rate.
Also, prior cold work increases the spheroidizing reaction rate.
Q.5 (d) Solution:
Laws of Coulomb Friction: The friction, that exists between two surfaces which are not
lubricated, is known as solid friction. The two surfaces may be at rest or one of the surface
is moving and other surface is at rest. The fallowing are the laws of Coulomb’s friction :
1. The force of friction acts in the opposite direction in which the surface is having a
tendency to move.
2. The force of friction is equal to the force applied to the surface, as long as the surface
is at rest.
3. When the surface is at the verge of motion, the force of friction is maximum and this
maximum frictional force is called the limiting frictional force.
4. The limiting frictional force bears a constant ratio to the normal reaction between
two surfaces.
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5. The limiting frictional force does not depend upon the shape and areas of the surfaces
in contact.
6. The ratio between limiting friction and normal reaction is slightly less when the
two surfaces are in motion.
7. The force of friction is independent of the velocity of sliding.
The above Laws of solid friction are also called laws of static and dynamic friction.
Q.5 (e) Solution:

2P P
B
A C
L L
2 2
Flexural rigidity = EI
3 2
PL3 2 P ⎛ L ⎞ 2P ⎛ L ⎞ L
Deflection at free end, δ = + ×⎜ ⎟ + ×⎜ ⎟ ×
3EI 3EI ⎝ 2 ⎠ 2 EI ⎝ 2 ⎠ 2
PL3 PL3 P L3
= + + ×
3EI 12 EI EI 8
PL3 ⎛ 1 1 1 ⎞ PL3 ⎡ 8 + 2 + 3 ⎤
= ⎜ + + ⎟=
EI ⎝ 3 12 8 ⎠ EI ⎢⎣ 24 ⎥⎦
13 PL3 L
δ = ≤ (Given)
24 EI 500
EI 24 1 24EI 1 EI
P ≤ 2 × × = 2 =
L 500 13 6500L 270.83 L2
Q.6 (a) Solution:
Rolling is the process of reducing the thickness or changing the cross section of a long
workpiece by compressive forces applied through a set of rolls, as shown in figure below.
Rolling is a major manufacturing process of sheets and other cross sections of large length
like I beam, railroads etc. It is one of a metal forming process in which the metal work piece
is compressed between a set of rolls where it reduces its cross section area and increases its
length. This process gives high production rate, surface finish and grain structure which
make it a most suitable metal forming process for large length same cross section work
pieces but high set up cost of rolling machine makes it as an alternative process.
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w0 (Top roll removed)

V0 R α
Vr
h0 Roll No-slip
Workpiece
point
Vf
V0 Vf
L Workpiece Friction
Roll wf forces
R
Roll
hf Energy zone Gap L Exit zone
Figure (i) Rolling Process
1. Shape rolling: In shape rolling, the work is deformed into a contoured cross section.
Products made by shape rolling include construction shapes such as I-beams, L-
beams, and U channels; rails for railroad tracks; and round and square bars and rods.
Most of the principles that apply in flat rolling are also applicable to shape rolling.
Shaping rolls are more complicated; and the work, usually starting as a square shape.
Designing the sequence of intermediate shapes and corresponding rolls is called
roll-pass design. Its goal is to achieve uniform deformation throughout the cross
section in each reduction.
2. Transverse rolling or Roll forging: In this operation (also called cross rolling), the
cross section of a round bar is shaped by passing it through a pair of rolls with profiled
grooves (Fig. (ii)). Roll forging typically is used to produce tapered shafts and leaf
springs, table knives, and hand tools; it also may be used as a preliminary forming
operation, to be followed by other forging processes.
Figure (ii)
Transverse Rolling
3. Skew Rolling: A process similar to roll forging is skew rolling, typically used for
making ball bearings . Round wire or rod is fed into the roll gap, and roughly spherical
blanks are formed continuously by the action of the rotating rolls (Figure (iii))
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Stock
Semi- finished ball
Figure (iii) Skew rolling

4. Ring Rolling: In ring rolling, a thick ring is expanded into a large diameter thinner
one. The ring is placed between two rolls, one of which is driven while the other is idle
(Figure (iv)). Its thickness is reduced by bringing the rolls closer together as they rotate.
Since the volume of the ring material remains constant during plastic deformation
(volume constancy), the reduction in ring thickness results in an increase in its diameter.
Typical applications of ring rolling are large rings for rockets and turbines.
Rounding roll
Idler roll
Edging roll Main roll (driven)
Workpiece
Figure (iv) Illustration of a ring-rolling operation.

Thickness reduction results in an increase in the part diameter
5. Thread Rolling: Thread rolling is a cold-forming process by which straight or tapered

threads are formed on round rods or wire. The threads are formed on the rod or wire
with each stroke of a pair of flat reciprocating dies In another method, threads are
formed with rotary dies , The thread-rolling process has the advantages of generating
threads with good strength (due to cold working) and without any loss of material
(scrap). The surface finish produced is very smooth, and the process induces
compressive residual stresses on the workpiece surfaces, thus improving fatigue life.
6. Rotary Tube Piercing or Roll Piercing: Ring rolling is a specialized hot working process
for making seamless thick-walled tubes. It utilizes two opposing rolls, and hence it is
grouped with the rolling processes. The process is based on the principle that when a
solid cylindrical part is twisted on its circumference and high tensile stresses are
developed at its center. If stress is high enough, an internal crack is formed. In roll
piercing, this principle is exploited by the setup shown in Figure (v).
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Rolls
Starting rod
Mandral
Finished tube
Figure (v) Rotary Tube Piercing
Q.6 (b) Solution:

Initial diameter of billet (Di) = 200 mm
Initial height of billet (hi) = 70 mm
Final height of billet (hf) = 40 mm
Final diameter of billet = Df
Coefficient of friction, μ = 0.05
Flow curve equation, μi = 240 (0.02 + ∈)0.45
As the volume remains constant,
π 2 π
Di hi = D2f h f
4 4
1/2 1/2
⎛h ⎞ ⎛ 70 ⎞
Df = Di ⎜ i ⎟ = 200 ⎜ ⎟ = 264.57 mm
⎝ hf ⎠ ⎝ 40 ⎠
Df
Radius, Rf = = 132.28 mm
2
Let us check now the sticking radius.
Sticking radius in case of circular billet is given by, using Trasca’s Theory:
hf ⎛ 1 ⎞ 40 ⎛ 1 ⎞
Sticking radius (Rs) = R f − ln ⎜ ⎟ = 132.28 − ln ⎜ ⎟
2μ ⎝ 2μ ⎠ 2 × 0.05 ⎝ 2 × 0.05 ⎠
= –788.754 mm
Have, negative sign indicates that there will be no sticking.
⎛h ⎞ ⎛ 7⎞
i
True strain, ∈ = ln ⎜ h ⎟ = ln ⎜⎝ 4 ⎟⎠ = 0.559
⎝ f⎠
Mean flow stress, σ0 = σf = 240(0.02 + 0.559)0.45 = 187.68 MPa
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Forging stress in case of no sticking is given as

2μ
(R−r )
Pf1 = 2K ′ e h
for circular disc case, plane stress condition prevails
2K′ = σ 0
2μ 2 × 0.05
( R −r ) (132.28 − r )
Pf1 = σ 0 eh = 187.68 e 40
(132.28 − r )
= 187.68 e 400
R 132.28 ⎛ 132.28 − r ⎞
⎜⎝ ⎟
400 ⎠
Forging load, F = ∫ Pf 1 (2πrdr ) = 2π × 187.68 ∫ re dr
0 0
132.28
⎡ ⎛ 132.28 − r ⎞ ⎛ 132.28 − r ⎞ ⎤
= 1179.23 ⎢r ( −400)exp ⎜ ⎟ − ∫ ( −400)exp ⎜ ⎟ dr
⎣ ⎝ 400 ⎠ ⎝ 400 ⎠ ⎥⎦ 0
132.28
⎡ ⎛ 132.28 − r ⎞ ⎛ 132.28 − r ⎞ ⎤
= 1179.23 ⎢ −400r exp ⎜ ⎟ − ( −(400))2 exp ⎜ ⎟
⎣ ⎝ 400 ⎠ ⎝ 400 ⎠ ⎥⎦ 0
⎡ ⎛ 132.28 ⎞ ⎤
= 1179.23 ⎢( −400 × 132.28 − 4002 ) − 0 + 4002 exp ⎜
⎣ ⎝ 400 ⎟⎠ ⎥⎦
F = 11.555 MN
Load 11.555 × 106
Mean die pressure = = = 210.18 MPa
Total area π × (264.57)2
4
Maximum die pressure: Pr1 r=0
2μ
( R −r )
Pmax = σ0 eh
r =0
⎡ 2 μR ⎤ ⎡ 2 × 0.05 × 132.28 ⎤
= 187.68 exp ⎢ ⎥ = 187.68 exp ⎢ ⎥⎦
⎣ h ⎦ ⎣ 40
= 261.24 MPa
Q.6 (c) Solution:
Just-in-time (JIT) manufacturing, also known as just-in-time production or the Toyota
Production System (TPS), is a methodology aimed primarily at reducing flow times
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within production system as well as response times from suppliers and to customers.
The objectives of JIT are achieved as a part of computer integrated manufacturing through
several physical systems or projects. Some of the main JIT objectives are as follows:
• To reduce the set-up times and lot sizes.
• To achieve ‘zero defects’ goal in manufacturing.
• To focus on continuous improvement.
• To concentrate on involving workers and using their knowledge to a greater extent.
• Layout of equipments in such a way so as to minimizes both travel distances and
inventories between the machines.
• To reduce inventories and thus economize on inventory carrying costs.
• To eliminate waste (such as long set-up times, zigzag material flow, scrap, machine
breakdown, higher stocks, rework, inspection etc.).
• To identify any problem related to waste and solve that through total employees
involvement.
• To eliminate all non- value adding activities by systematically identifying these.
• To cross –train the workers in multi-functions to maintain and enable them to run
several machines at a time.
The JIT system is aimed at improving profits and return on investment through cost
reductions, inventory reductions and quality improvements. These benefits explain wide
acceptance of JIT in industry. The following are some benefits of a JIT system as follows:
• Close supplier/customer relations
• Fast response to engineering changes
• Improved competitive position
• Improved equipment efficiency
• Improved worker efficiency
• Improved worker motivation
• Increased equipment utilization
• Increased flexibility
• Less scrap
• Lower overheads
• Reduced product cost
• Reduced production lead time
• Reduced purchasing lot size
• Reduced raw materials/parts
• Reduced space requirements
• Increased productivity
• Reduced inventories
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• Reduced labour requirements

• Reduced work-in-process
Q.7 (a) Solution:

Power, P = 310 kW
N = 117 rpm
2 πN 2 π × 117
Angular speed, ω = = = 12.252 rad/ s
60 60
Maximum shear stress, τper = 100 MPa = 100 N/mm2
P 310 × 10 3
Torque = = = 25302 N .m
ω 12.252
T = 25.302 × 106 N.mm
π 3
T ≤ ds × τ
16
16T 16 × 25.302 × 10 6
ds3 ≥ =
πτ π × 100
ds ≥ 108.82 mm
T τ
=
J d /2
Same torque and same material, so
JH = Js
π ⎛ D4 − d 4 ⎞ ds3
Polar modulus of hollow shaft = = π ×
16 ⎜⎝ D ⎟⎠ 16
D4 − d 4
= ds3
D
d = 0.65D
D3(1 – 0.654) = ds3
1/3
⎡ (108.82)3 ⎤ 108.82
D = ⎢ 4 ⎥
= = 116.184 mm
⎣⎢ (1 − 0.65 ) ⎦⎥ (0.8215)0.333
d = 0.65 × 116.184 = 75.52 mm
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As − Ah ds2 − (D2 − d 2 )
% Saving in materials = × 100 = × 100
As ds2
(108.82)2 − (116.184 2 − 75.52 2 )
= × 100 = 34.17%
(108.82)2
Q.7 (b) Solution:

6 kN
2 kN/m
C
A B
2m 1m
RA = 5 kN RB =7 kN
Taking moment about A,

2 × 3 × 1.5 + 6 × 2 = 3 RB
9 + 12 = 3 RB
RB = 7 kN
RA + RB = 2 × 3 + 6 = 12
RA = 12 – RB = 12 – 7 = 5 kN
We have to find out bending moment at section located at a distance 1 m from right hand
support,
MC = 5 × 2 – 2 × 2 × 1 = 10 – 4 = 6 kN.m
= 6 × 106 N.mm (sagging)
Shear force, at C, FC = 5 – 2 × 2 = 1 (Just left to C)
FC ′ = 1 – 6 = –5 kN (Just right to C)
Jump in shear force at C = 6 kN ↓
MC × yD MC × 50
Bending stress, σb = =
I xx I xx
75 × 200 3 60 × 1803
Ixx = − = 50 × 106 – 29.16 × 106
12 12
= 20.84 × 106 mm4
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10 mm
40 mm
90 mm
50 mm
NA NA
90 mm
15 mm
10 mm
75 mm
6 × 106 × 50
σb = 6
= 14.4 N/ mm 2
20.84 × 10
= 14.4 MPa (Sagging moment) (Compressive)
Shear stress at D:
Fay
τD =
Ib
Here, F = 6000 N,
b = 15 mm
ay (about neutral axis) = 15 × 40 × 70 + 75 × 10 × 95 = 113250 mm3 for ay calculation,
please refer shaded area of I-section as shown below:
113250 × 5000
τD = = 1.81 N/mm2
20.84 × 106 × 15
2
14.4 ⎛ 14.4 ⎞ 2
Principal stresses, σ 1,2 = − ± ⎜− ⎟ + (1.81)
2 ⎝ 2 ⎠
= −7.2 ± ( −7.2 )2 + (1.81)2

= –7.2 ± 7.42
σ 1 = –14.62 N/mm2
σ 2 = 0.22 N/mm2
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Q.7 (c) (i) Solution:
a
P
M
N
C
80 kN
0.05 m
Q
FBD of cross-section a
From the force equilibrium:
ΣFx = 0
⇒ N – 80 = 0
N = 80 kN
From moment equilibrium:
M = 80 × 0.05 = 4 kN-m
Cross-section area, A = 200 × 10 = 2000 mm2 = 0.002 m2
1
MOI about Neutral Axis, I = × 0.01 × (0.2)3 = 6.667 × 10–6 m4
12
The normal stress developed is the combination of axial and bending stress. Thus
N My
σ = ±
A I
(y is the distance from the centroidal transverse axis)
80 × 10 3 4 × 10 3 × y
At section - aa, σaa = − = 40 – 0.6y MPa
0.002 6.667 × 10 −6
[where, y is in mm]
At point Q, σ Q = 40 – 0.6(–100) MPa
= 100 MPa (Tensile stress)
at a point P, y = 100 mm
σP = 40 – 0.6(100) = –20 MPa
i.e. σP = 20 MPa (Compressive stress)
For plotting the distribution of bending stress, we have to find out location of neutral axis:
20 MPa
NA
0.15 m y
80 kN
0.05 m
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At neutral axis, σA = 0
⇒ 40 – 0.6y = 0
40
y = = 66.67 mm
0.6
Q.7 (c) (ii) Solution:
4 kN 2 kN
2m 2m
A B
tA/B = –10 mm
10 m
3
CG
8 m
–4 kN.m
3
CG
–16 kN.m
As per moment area method:
1
tA/B = (Area AB)X A
EI
1 ⎡ 1 ⎛ 10 ⎞ 1 ⎛ 8⎞ ⎤ 4
–10 =
⎛ 50 h 3 ⎞ ⎢ − 2 (2)(4) ⎜⎝ 3 ⎟⎠ − 2 (4)(16) ⎜⎝ 3 ⎟⎠ ⎥ (1000 )
⎣ ⎦
10000 ⎜ ⎟
⎝ 12 ⎠
3 ⎡ 296 ⎤
= − (1000 4 )
125000h ⎢⎣ 3 ⎥⎦
3
( −296)(1000 4 )
h3 =
(125000)( −10)
h = 618.67 mm
Q.8 (a) Solution:

1. Stellite:
Composition: Cobalt - 57%, Chromium - 28-32%, Tungsten-11-13%, Carbon - 2-3%, Silicon-
1-2%, Iron-1%, Nickel-1%, Other-1.5%
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Applications:
• Saw teeth, hardfacing and acid-resistant machine parts.
• Poppet valves, valve seats and exhaust valves of IC Engine.
• Machine gun barrels
• Medical applications including manufacturing of artificial hip joints, other bone
replacement and cost structure of dental prosthesis.
• Turning tools for lathes
2. Phosphor Bronze:
Composition: Tin - 4.2-5.8%, Phosphorus - 0.030-0.35%, Iron - 0.10%(max), Lead -
0.05%(max), Zin - 0.3%(max), Copper - Remainder
Applications:
• Springs, fasteners and bolts
• Digital electronics, automatic controllers
• Acoustic guitar strings
• Used for molding processes like press punching, bending and drawing
3. Muntz Metal: (Also known as α -β
β brass)
Composition: Cu Fe Pb Zn
Min/max 59.0 - 63.0 0.07 0.09 Remainder
Nominal 60 40
Applications:
• Springs
• Components of electrical switches and sockets
• Tubes
• Plumbing goods and fasterners
4. AlNiCo:
Composition: Aluminium - 8-12%, Nickel - 15-26%,Cobalt - 5-24%, upto 6% Copper, upto
1% Titanium, balance is Fe
Applications:
• Very high temperature applications
• MRI
• Medical equipment
• Cow magnets (to prevent hardware disease in cattle)
• Magnetic pump couplings
• Used to make permananet magnets
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5. Naval brass:
Composition: Copper - ~59%, Zinc - 40%,Tin - 1%, with a trace amount of lead.
Applications:
• Sea water service applications
• Industrial purpose
• Marine construction
Q.8 (b) Solution:
O
xC1
xC = h
xC2
C1
C2 R
With reference to the origin O at the apex of the cone as shown above the centroid of the
cone alone lies at
⎛ 3⎞
xC1 = ⎜ ⎟ h
⎝ 4⎠
and the centroid of the hemisphere lies at
⎛ 3⎞
xC2 = h + ⎜ ⎟ R
⎝ 8⎠
Recolecting that the volume of the cone is:
⎛ 1⎞ 2
V 1 = ⎜⎝ ⎟⎠ πR h
3
and the volume of the hemisphere is:
⎛ 2⎞ 3
V 2 = ⎜⎝ ⎟⎠ πR
3
The centroid of the composite volume must be located at interface of cone and hemisphere.
So, xC(V1 + V2) = xC1 V1 + xC2 V2
⎛1 2 ⎞ ⎛ 3⎞ ⎛ 1 ⎞ ⎛ 3 ⎞⎛2 ⎞
h ⎜ πR 2 h + πR 3 ⎟ = ⎜ ⎟ h ⎜ πR 2 h⎟ + ⎜ h + R⎟ ⎜ πR 3 ⎟
⎝3 3 ⎠ ⎝ 4⎠ ⎝ 3 ⎠ ⎝ 8 ⎠⎝3 ⎠
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⎛1 2 ⎞ 1 2 1
h ⎜ πR 2 h + πR 3 ⎟ = πR 2 h 2 + πR 3h + πR 4
⎝3 3 ⎠ 4 3 4
h2 2 h2 2 R2
or, + Rh = + Rh +
3 3 4 3 4
h2 = 3R 2
h
= 3
R
Q.8 (c)(i) Solution:
Centroid can also be termed as the geometrical center of a body. The center of mass
coincides with the Centroid in a body with uniform density. There are following
differences between center of gravity and Centroid:
1. The term "Center of gravity" applies to the bodies with mass and weight, while the
term "Centroid" applies to plane areas.
2. Center of gravity of a body is the point through which the resultant gravitational
force (weight) of the body acts for any orientation of the body while Centroid is the
point in a plane area such that the moment of the area, about any axis, through that
point is zero. Center of gravity is the point at which a object can be suspended and
be in perfect equilibrium.
3. Centroid should be in the body as it is the geometrical centre of figures (no mass)
Centre of gravity depends on mass density of the body and it is related to distribution
of mass. Centroid can be termed as the geometrical centre of a body. It is related to
the distribution of length, area and volume.
Q.8 (c)(ii) Solution:

Weight of first body, W1 = 500 N
Weight of second body, W2 = 900 N
Coefficient of friction for first body,
μ1 = 0.15
Coefficient of friction for second body,
μ2 = 0.40
Let α = Inclination of plane
T = Tension in cord
R 1 = Normal reaction for first body
R 2 = Normal reaction for second body
F1 = Force of friction between 1st body and plane = μ1R1
F2 = Force of friction between 2nd body and plane = μ2R2
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R2
R1 T R2
μ2
=
T F2
α
R1
=μ
1
900 N
F1
α
α
500 N
Forces on first body:
500sinα = T + F1 = T + μ1R1 = T + 0.15R1 ... (i)
Resolving forces normal to the plane,
500cosα = R 1
Equation (i) becomes,
500sinα = T + 0.15 × 500 cosα
T = 500 sinα – 75 cosα ... (ii)
Forces on second body: R 2 = 900 cosα
900 sinα + T = 0.4 × 900cosα = 360 cosα
T = 360 cosα – 900 sinα ... (iii)
From equation (ii) and (iii)
500 sinα – 75 cosα = 360 cosα – 900 sinα
500 sinα + 900 sinα = (360 + 75) cosα
(360 + 75)
tanα = = 0.31071
(500 + 900)
α = tan–1 (0.31071) = 17.26°
Tension in the chord: T = 500 sinα – 75 cosα
T = 500 sin (17.26°) – 75 cos (17.26°)
T = 76.73 N

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ME - R S E, Ind. Maintenance Engg. Prod. Engg. Mat. Sci.-1 SOMMech-2 - SOL - 2551

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ESE-2018 Mechanical Engineering

Section A : Renewable Source of Energy, Industrial and Maintenance Engineering

from figure is clear that:

609.5238 609.5238 × 3600

• Corrosive wear (chemical nature).

= ρA0u0 = ρA1u1 = ρA2u2

Thrust on the rotor, F = m u0 − m u2

= 4(1 – a)(1 – 3a)

0.2 1/3 0.4 0.6 1

(c) Based on operating temperature

Figure: Single Basin tidal plant

1. Total work done in filling or emptying the basin (h to h0)

0.75 × 539.865 × 106 × 3600

Different network paths are:

Reduction in project duration = 17 – 15 = 2 days

2DC0 2 × 225 × 100

2DC0 2 × 225 × 100

Q2* = 448.21 < 550 < Q < 700, (not feasible)

2DC0 2 × 225 × 100

Calculation of total cost:

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

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

(ii) Useful for construction projects Useful for R & D projects

(iii) Based on deterministic model Based on probabilistic model

(iv) CPM can control both time and

Figure (i) Seismic instrument

Figure (ii): Response of a vibration measuring instrument

Inital reliability of system R(s) = R(C1) × R(C2) × R(C3) × R(C4) × R(C5)

on the scope of the analysis. FTA may be undertaken independently, or in conjuction

Section B : Production Engineering & Material Science - 1, SOM & Mechanics - 2

Q.5 (b) Solution:

Q.5 (c) Solution:

Full annealing 1500

0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6

Spheroidizing: Medium- and high-carbon steels having a microstructure containing even

Q.5 (e) Solution:

w0 (Top roll removed)

Figure (i) Rolling Process

Semi- finished ball

Figure (iii) Skew rolling

Figure (iv) Illustration of a ring-rolling operation.

5. Thread Rolling: Thread rolling is a cold-forming process by which straight or tapered

Figure (v) Rotary Tube Piercing

Q.6 (b) Solution:

Forging stress in case of no sticking is given as

Maximum die pressure: Pr1 r=0

• Reduced labour requirements

Q.7 (a) Solution:

Q.7 (b) Solution:

Taking moment about A,

= −7.2 ± ( −7.2 )2 + (1.81)2

Q.8 (a) Solution:

So, xC(V1 + V2) = xC1 V1 + xC2 V2

Q.8 (c)(ii) Solution:

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