ESE-2018 Mains Test Series: Mechanical Engineering Test No: 13

Detailed Solutions
ESE-2018 Mechanical Engineering

Mains Test Series Test No : 13
Section A
Q.1.(a) Solution:
1. Metal matrix composites find extensive use in the structures of helicopters,
satellite, electrical contacts, jet engines, power reactors and high temperature
engine components.
2. Ceramic-matrix composites are used in jet engines, automobile engines,
pressure vessels, cutting tools, dies for extrusion and wire-drawing, deep-sea
equipment etc.
3. Shape memory alloys are used for space applications (fold them at room
temperature for carrying and heat then to bring to original shape), for clamps,
connectors, seals, eye glass frames and antiscaled valves fitted in piping system,
in sinks, tubs and shower.
4. The alloys of chromium and nickel are used for electrically heated appliances
working at temperatures above 850°C for muffle furnaces in the form of wires for
heating elements, as sheet or cast plate for furnace bottom, tubes for thermocouple
sheaths, heating coils or elements (trade name chromel or nichrome) for furnaces
in view of its high electrical resistance.
5. Dow metal has magnesium 85 to 95%, aluminium up to 12%, and little amount of
mangnese. It can be cast, forged, rolled and drawn into wires, tubes and extruded
into sheets. Dow metal can be welded and machined. It is light and is used for
making crank cases, head and fuel tanks of area engines and other parts of
automobile engines and aircraft.
10 | ESE 2018 : MAINS TEST SERIES
Q.1 (b) Solution:

Vibration and chatter can have significant effects on product quality and the productivity
of metalworking operations. Chatter, generally defined as self-excited vibration, can
occur in rolling as well as in extrusion, drawing, machining, and grinding operations.
In rolling, it leads to periodic variations in the thickness of the rolled sheet and in its
surface finish and, consequently, can lead to excessive scrap. Chatter in rolling has
been found to occur predominantly in tandem mills. Chatter is very detrimental to
productivity; it has been estimated, for example, that modern rolling mills could operate
at up to 50% higher speeds were it not for chatter. Chatter is a very complex phenomenon
and results from interactions between the structural dynamics of the mill stand and the
dynamics of the rolling operation. Rolling speed and lubrication are found to be the
two most important parameters. Although not always practical to implement, it also
has been suggested that chatter can be reduced by increasing the distance between the
stands of the rolling mill, increasing the strip width, decreasing the reduction per pass
(draft), increasing the roll radius, increasing the strip-roll friction, and incorporating
dampers in the roll supports.
Q.1 (c) Solution:

TIC at EOQ without backorder,
TIC* = 2 DC 0C h = 2 × 5000 × 50 × (0.15 × 100)
= `2738.613
Total inventory cost with optimum backordering is
⎛ Cb ⎞
(TIC)*b = 2 DC 0C h × ⎜ ⎟
⎝ Cb + C h ⎠
⎛ 0.1 × 100 ⎞
= 2 × 5000 × 50 × (0.15 × 100) ⎜
⎝ 0.1 × 100 + 0.15 × 100 ⎟⎠
⎛ 15 × 10 ⎞
= 2 × 5000 × 50 ⎜
⎝ 25 ⎟⎠
(TIC)*b = `1732.05
(TIC )* − (TIC )b* (2738.613 − 1732.05)
% Saving = *
× 100% = × 100
(TIC ) 2738.613
= 36.75% Answer
2 DC 0 2 × 5000 × 50
(EOQ)witout backordering = =
Ch 0.15 × 100
= 182.574 units
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Test No : 13 MECHANICAL ENGINEERING | 11
2 DC 0 ⎛ Cb + C h ⎞ 2 × 5000 × 50 ⎛ 15 + 10 ⎞
(EOQ)wit backordering = ×⎜ = ×⎜
Ch ⎝ C b ⎟⎠ 0.15 × 100 ⎝ 10 ⎟⎠
= 288.675 units
⎛ 288.675 − 182.574 ⎞
%change in EOQ = ⎜ ⎟ × 100% = 58.114% Answer
⎝ 182.574 ⎠
Quantity ordered at EOQ with backordering is 58.114% more than without backordering.
Q.1 (d) Solution:

If Σx = 0, then least square method can be used.
Year(X1) Demand in 1000 units(y) Deviation of x1 from 2010(x) x2 xy y2
2005 106 –5 25 –530 11236
2006 97 –4 16 –388 9409
2007 85 –3 9 –265 7225
2008 75 –2 4 –150 5625
2009 80 –1 1 –80 6400
2010 72 0 0 0 5184
2011 65 1 1 65 4225
2012 60 2 4 120 3600
2013 55 3 9 165 3025
2014 51 4 16 204 2601
2015 47 5 25 235 2209
n = 11 Σy = 793 Σx = 0 Σx2 = 110 Σxy = –624 Σy2 = 60739
Assume best line of fit as,

y = a + bx
Now, Σy = Σa + bΣx
⇒ 793 = 11a + b × 0
793
a = = 72.091
11
Σxy = aΣx + bΣx2
⇒ – 624 = 72.091 × 0 + b × 110
624
⇒ b = − = −5.672727
110
Demand in 2017, for 2017, x = 7
Now, y = a + bx = 72.091 – 5.672727 × 7
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y = 32.382 Answer
nΣxy − ( Σx )( Σy )
Corelation coefficient,r =
[nΣx 2 − ( Σx )2 ] [nΣy 2 − ( Σy )2 ]
11 × ( −624) − (0 × 793)
= = −0.9956
[11 × 110 − 0 [11 × 60739 − 7932
There is strong negative corelation of demand with upcoming year.
Q.1.(e) (i) Solution:

1.With respect to composition and heat treatment:
Gray iron: 2.5 to 4.0 wt% C and 1 to 3 wt% Si. There is no heat treatment process needed
after solidification for most gray cast irons.
Malleable iron: 2.5 to 4.0 wt% C and less that 1.0 wt% Si. White iron is heated in a non-
oxidizing atmosphere and at a temperature between 800 and 900°C for an extended
time duration.
2.With respect to microstructure:
Gray iron: Graphite flakes are embedded in a ferrite or pearlite matrix.
Malleable iron: Graphite clusters are embedded in a ferrite or pearlite marix.
3.With respect to mechanical characteristics:
Gray iron: Relatively weak and brittle in tension, good capacity for vibration damping.
Malleable iron: Moderate strength and ductility.
Q.1.(e)(ii) Solution:
Advantages of induction hardening heat treatment process are:
1. Time required is very small hence the process is very quick and productivity is
high.
2. Absence of scaling
3. Process can be automated
4. Reduced distortion
5. Depth of hardness can be controlled easily.
6. Decarburizing do not occur due to high speed grain growth.
Q.2 (a) Solution:

⎛ Area ⎞ 2 × 350 × 250 + 2 × 50 × 350 + 2 × 50 × 250
⎜⎝ ⎟⎠ =
Volume Casting 350 × 250 × 50
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⎛ A⎞ 235000
⎜⎝ ⎟⎠ = = 0.0537
V C 4375000
Volume of riser = 0.26 × Volume of casting (as given)
Vr = 0.26 × 4375000 = 1137500 mm3
for side placement of riser, h = d (optimum size)
π 3
Vr = dr = 1137500
4
1/3
⎛ 4 × 1137500 ⎞
dr = ⎜ ⎟⎠ = 113.14 mm
⎝ π
This riser diameter is far greater than thickness of casting (i.e. 50 mm). As the riser should
V ⎛V ⎞
solidify after casting, ⎛⎜ ⎞⎟ ≥⎜ ⎟
⎝ A ⎠ riser ⎝ A ⎠ Casting
⎛ A⎞ 2 πr 2 + 2 πrh 6πr 2 3 6
⎜⎝ ⎟⎠ = = = =
V r πr 2 h 2 πr 3 r d
(h = d for optimum area)
⎛ A⎞ 6
⎜⎝ ⎟⎠ = = 0.0530 ... (i)
V r 113.14
⎛ A⎞ ⎛ A⎞
for ideal casting ⎜⎝ ⎟⎠ ≤ ⎜⎝ ⎟⎠ i.e. 0.0530 ≤ 0.0537
V r V C
Solidification time justify this placement
for top placement,
d
h = (Optimum area basis)
2
π 2 d πd 3
Vr = d × = = 1137500
4 2 8
1/3
⎛ 8 × 1137500 ⎞
dr = ⎜ ⎟⎠ = 142.55 mm
⎝ π
dr = 142.55 (less than the c/s dimensions of casting)
⎛ A⎞ 6 6
⎜ ⎟ = = = 0.042 ... (ii)
⎝ V ⎠r dr 142.55
⎛ A⎞ ⎛ A⎞
for ideal casting ⎜⎝ ⎟⎠ ≤ ⎜⎝ ⎟⎠ i.e. 0.042 < 0.0537
V r V C
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So the solidification time for top placement of riser justifies the size of riser. We can
see by comparing equation (i) and (ii).
Diameter of riser = 142.55 mm Answer
142.55
Height of riser = = 71.275 mm Answer
2
Pipe
h
Riser
H d
Casting
Pipe height: We know that pipe cavity compensates the shrinkage allowance which is
th
1
around ⎛⎜ ⎞⎟ of riser volume.
⎝ 6⎠
7
VS = × 350 × 250 × 50 = 306250 mm3
100
1π 2
dr H = 306250
64
24 × 306250
H = = 115.134 mm Answer
π(142.55)2
Hence the new height of riser should be more than 115.134 mm in order to avoid pipe
extension in to the casting.
Q.2 (b) Solution:

1. Coining: This is essentially a closed-die forging process that is typically used in the
minting of coins, medallions, and jewelry. The blank or slug is coined in a completely
closed die cavity. In order to produce fine details (for example, the detail on newly
minted coins), the pressures required can be as high as five or six times the strength of
the material. On some parts, several coining operations may be required. Lubricants
cannot be applied in coining, because they can become entrapped in the die cavities
and (being incompressible) prevent the full reproduction of die surface details and
surface finish.
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Upper die
Retaining ring Die holder
Die holder Workpiece

Lower die
Coined part
Schematic illustration of the coining process
Marking parts with letters and numbers also can be done rapidly through coining. In
addition, the process is used with forgings and other products to improve surface finish
and to impart the desired dimensional accuracy with little or no change in part size,
called sizing, this process requires high pressures.
2. Heading: Also called upset forging, heading is essentially an upsetting operation,
usually performed on the end of a round rod or wire in order to increase the cross
section. Typical products are nails, bolt heads, screws, rivets, and various other fasteners.
Heading can be carried out cold, warm, or hot. An important consideration in heading
is the tendency for the bar to buckle if its unsupported length-to-diameter ratio is too
high. This ratio usually is limited to less than 3:1, but with appropriate dies, it can be
higher. For example, higher ratios can be accommodated if the diameter of the die
cavity is not more than 1.5 times the bar diameter.
Kickout pin Die
Blank
Punch
1.
Head formed
in punch
2.
Head formed
in die
3.
Heading operation to form heads
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3. Incremental forging: In this process, a tool forges a blank into a shape in several
small steps. The operation is somewhat similar to cogging, in which The die penetrates
the blank to different depths along the surface. Because of the smaller area of contact
with the die, the process requires much lower forces compared with conventional
impression-die forging, and the tools are simpler and less costly.
4. Isothermal forging: Also known as hot-die forging, this process heats the dies to the
same temperature as that of the hot workpiece. Because the workpiece remains hot, its
flow strength and high ductility are maintained during forging. Also, the forging load
is low, and material flow within the die cavity is improved. Complex parts with good
dimensional accuracy can be isothermally forged to near-net shape by one stroke in a
hydraulic press.
5. Rotary swaging: In this, a solid rod or tube is subjected to radial impact forces by a
set of reciprocating dies of the machine. The die movements are obtained by means of
a set of rollers in a cage in an action similar to that of A roller bearing. The workpiece is
stationary and the dies rotate (while moving radially in their slots), striking the
workpiece at rates as high as 20 strokes per second as shown in figure below.
Planetary
Retainer rollers
Hammer
Die Driven
Q.2 (c) Solution:

Piezoelectric transducer consists of quartz crystal which is made from silicon and oxygen
arranged in crystalline structure (SiO2). Generally, unit cell (basic repeating unit) of all
crystal is symmetrical but in piezoelectric quartz crystal it is not. Piezoelectric crystals
are electrically neutral. The atoms inside them may not be symmetrically arranged but
their electrical charges are balanced means positive charges cancel out negative charge.
The quartz crystal has unique property of generating electrical polarity when mechanical
stress applied on it along certain plane. Basically, there are two types of stress. One is
compressive stress and other is tensile stress.
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Unstressed
No charge induced
Quartz
Compressive stress
+ –
Stressed Quartz Charges induced in one way
+ –
Tensile stress
– +
– Stressed Quartz + Charges induced in other way
– +
When there is unstressed quartz no charges induce on it. In case of compressive stress,
positive charges are induced in one side and negative charges are induced in opposite
side. The crystal size gets thinner and longer due to compressive stress. In case of
tensile stress, charges are induced in reverse as compare to compressive stress and
quartz crystal gets shorter and fatter. Piezoelectric transducer is based on principle of
piezoelectric effect. Piezoelectric effect states that when mechanical stress or forces are
applied on quartz crystal, produce electrical charges on quartz crystal surface. The rate
of charge produced will be proportional to rate of change of mechanical stress applied
on it. Higher will be stress higher will be voltage.
Application of Piezoelectric Materials:
1. In microphones, the sound pressure is converted into electric signal and this
signal is ultimately amplified to produce louder sound.
2. Automobile seat belts lock in response to a rapid deceleration also done by
piezoelectric material.
3. It is also used in medical diagnostics.
4. It is used in electric lighter used in kitchens. Pressure made on piezoelectric
sensor creates an electric signal which ultimately causes flash to fire up.
5. They are used for studying high speed shock waves and blast waves.
6. Used in fertility treatment.
7. Used in Inkjet printers
8. It is also used in restaurants or airports where when a person steps near the door
and the door opens automatically. In this the concept used is when person is
near the door a pressure is exerted persons weight on the sensors due to which
the electric effect is produced and the door opens automatically.
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Examples of Piezoelectric Material

1. Barium Titanate.
2. Lead zirconate titanate (PZT).
3. Rochelle salt.
Advantages of Piezoelectric Transducer
1. No need of external force.
2. Easy to handle and use as it has small dimensions.
3. High frequency response it means the parameters change very rapidly.
Disadvantages of Piezoelectric Transducer
1. It is not suitable for measurement in static condition.
2. It is affected by temperatures.
3. Output is low so some external circuit is attached to it.
4. It is very difficult to give desired shape to this material and also desired strength.
Q.3 (a) Solution:

1. Hydraulic: A hydraulic actuator consists of cylinder or fluid motor that uses hydraulic
power to facilitate mechanical operation. The mechanical motion gives an output in
terms of linear, rotatory or oscillatory motion. As liquids are nearly impossible to
compress, a hydraulic actuator can exert a large force. The drawback of this approach
is its limited acceleration. The hydraulic cylinder consists of a hollow cylindrical tube
along which a piston can slide. The term single acting is used when the fluid pressure
is applied to just one side of the piston. The piston can move in only one direction, a
spring being frequently used to give the piston a return stroke. The term double acting
is used when pressure is applied on each side of the piston; any difference in pressure
between the two sides of the piston moves the piston to one side or the other.
2. Pneumatic: A pneumatic actuator converts energy formed by vacuum or compressed
air at high pressure into either linear or rotary motion. Pneumatic energy is desirable
for main engine controls because it can quickly respond in starting and stopping as the
power source does not need to be stored in reserve for operation. Moreover, pneumatic
actuators are safer, cheaper, and often more reliable and powerful than other actuators.
Pneumatic actuators enable considerable forces to be produced from relatively small
pressure changes. These forces are often used with valves to move diaphragms to affect
the flow of air through the valve.
3. Electric: An electric actuator is powered by a motor that converts electrical energy
into mechanical torque. The electrical energy is used to actuate equipment such as
multi-turn valves. Additionally, a brake is typically installed above the motor to prevent
the media from opening valve. If no brake is installed, the actuator will uncover the
opened valve and rotate it back to its closed position. If this continues to happen, the
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motor and actuator will eventually become damaged. It is one of the cleanest and most
readily available forms of actuator because it does not directly involve oil or other
fossil fuels.
4. Thermal or magnetic : Actuators which can be actuated by applying thermal or
magnetic energy have been used in commercial applications. Thermal actuators tend
to be compact, lightweight, economical and with high power density. These actuators
use shape memory materials (SMMs), such as shape memory alloys (SMAs) or magnetic
shape-memory alloys (MSMAs).
5. Mechanical: A mechanical actuator functions to execute movement by converting
one kind of motion, such as rotary motion, into another kind, such as linear motion. An
example is a rack and pinion. The operation of mechanical actuators is based on
combinations of structural components, such as gears and rails, or pulleys and chains.
Q.3 (b) Solution:

Precedence diagram:
3
F
C I 1
4
6 G
A
H K L
3
3 4 3
D
2 J
B 2
4
E
3
Using largest candidate rule:
Element C B G K A E F H L D J I
Ti(days) 6 4 4 4 3 3 3 3 3 2 2 1
Precedence A - C I, J - B C C, D K, I AB E, H F, G, H
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Workstation Element Ti Station time Idle time

I B 4
A 3 10 0
E 3
II C 6 10 0
G 4
III F 3
D 2 10 0
H 3
J 2
IV I 1
K 4 8 2
L 3
Cycle time = 10 days

Total work content = 38 days Answer
Number of work stations = 4
⎡ n × TC − TWC ⎤ ⎡ 4 × 10 − 38 ⎤
Balance delay = ⎢ ⎥ × 100% = ⎢ × 100% = 5% Answer
⎣ n × TC ⎦ ⎣ 4 × 10 ⎥⎦
TWC 38
Line efficiency = × 100 = × 100 = 95% Answer
n × TC 4 × 10
Smoothness index = (Maximum station time − Station time)2
SI = (10 − 10)2 + (10 − 10)2 + (10 − 10)2 + (10 − 8)2 = 2 Answer
Q.3.(c)(i)Solution:
A flexible manufacturing system (FMS) is an arrangement of machines interconnected
by a transport system. The transporter carries work to the machines on pallets or other
interface units so that work-machine registration is accurate, rapid and automatic. A
central computer controls both machines and transport system. FMS is called flexible
due to the reason that it is capable of processing a variety of different part styles
simultaneously at the workstation and quantities of production can be adjusted in
response to changing demand patterns.
The basic components of FMS are:
1. Workstations
2. Automated Material Handling and Storage system.
3. Computer Control System
1. Workstations: In present day application these workstations are typically computer
numerical control (CNC) machine tools that perform machining operation on families
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of parts. Flexible manufacturing systems are being designed with other type of processing
equipments including inspection stations, assembly works and sheet metal presses.
The various workstations are
(i) Machining centers
(ii) Load and unload stations
(iii) Assembly work stations
(iv) Inspection stations
(v) Forging stations
(vi) Sheet metal processing, etc
2. Automated Material Handling and Storage system: The various automated material
handling systems are used to transport work parts and subassembly parts between the
processing stations, sometimes incorporating storage into function. The various functions
of automated material handling and storage system are
(i) Random and independent movement of work parts between workstations
(ii) Handling of a variety of work part configurations
(iii) Temporary storage
(iv) Convenient access for loading and unloading of work parts
(v) Compatible with computer control
3. Computer Control System: It is used to coordinate the activities of the processing
stations and
the material handling system in the FMS. The various functions of computer control
system are:
(i) Control of each work station
(ii) Distribution of control instruction to work station
(iii) Production control
(vi) Traffic control
(v) Shuttle control
(vi) Work handling system and monitoring (vii) System performance monitoring and
reporting
The FMS is most suited for the mid variety, mid value production range.
Q.3.(c)(ii)Solution:
Components of JIT system are:
– Kanban
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– Reduced set-up time

– Smaller lot size
– Production smoothing
– Standardisation
– Uniform and invariable output rate
– Multifunction workers
– Streamlined process design
– Flexiblity and versatility
Benefits of JIT system are:
– Increased flexibility
– Less scrap
– Better quality
– Less raw material
– Less work-in-progress
– Fewer finished goods
– Increased teamwork
– Higher worker motivation
– Increased worker and equipment efficiency
– Saved space
– Increased productivity
Q.4 (a) Solution:

Minimum processing time on M1 is = 7
Maximum processing time on M2 is = 5
Maximum processing time on M3 is = 6
Minimum processing time on M4 is = 6
Minimum M1j ≥ Maximum M2j, Maximum M3j
Minimum M4j ≥ Maximum M2j, Maximum M3j
We can reduce this problem to n jobs on 2 machines. Processing times M1j + M2j + M3j
and M4j + M2j + M3j for each job and solving the problem.
Jobs
Combination
of Machines
P Q R S T
M1 + M2 + M3 18 20 12 15 19
M2 + M3 + M4 20 21 14 9 15
R–P–Q–T–S
Hence the required optimum sequence is R – P – Q – T – S.
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Machine
(→) Machine (M1) Machine (M2 ) Machine (M3) Machine (M4)
Job (↓) In time Out time In time Out time In time Out time In time Out time
R 0 7 7 9 9 12 12 21
P 7 18 18 21 21 25 25 38
Q 18 27 27 32 32 38 38 48
T 27 37 37 41 41 46 48 54
S 37 50 50 52 52 52 54 61
Make span time = 61

50
% Idle time for machine 1 = 100 − × 100 = 100 – 81.967% = 18.033%
61
16
61
18
% Idle time for machine 3 = 100 − × 100 = 100 –29.508% = 70.492%
61
45
61
0 7 18 27 37 50 61
Machine 1
Idle time = 18.033%
0 7 9 18 21 27 32 37 41 50 52 61
Machine 2
Idle time = 73.77%
0 9 12 21 25 32 38 41 46 52 61
Machine 3
Idle time = 70.492%
0 12 21 25 38 48 54 61
Machine 4
Idle time = 26.23%
where hatched area shows idle time
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Q.4 (b) Solution:

Subsystems of industrial robots include:
Actuators: Actuators are basically prime movers providing both force and motion.
Pneumatic cylinders, hydraulics, permanent magnet motors, stepper motors, linear
motors are some conventional actuators. More advanced ones are based on hi-tech
polymers, shape memory alloys, piezo patches, and pneumatic muscles. Brushless
servo motors also exist for low noise levels, and printed armature motors are used for
quick response.
Transmission systems: The transmission system used in robot to transmit power and
motion consists of chains, timing belts, metal belts, cables and pulleys and linkages.
Gear boxes and harmonic drives serve to provide speed reduction. Ball screws are
used with suitable mechanisms to convert rotary motion to linear motion and if needed
back to oscillatory motion. Drive stiffness is an important consideration in robotics
and so also is backlash.
Power supplies: Hydraulic and Pneumatic power packs: These consist of a motor driving
a positive displacement pump or compressor to generate the high pressure fluid flow. In
using hydraulic systems the necessity of having an oil tank increases the weight of the
system, additionally the issue of ensuring that the oil is free of contaminants is to be
handled. In pneumatics power pack dry air is desired. Electric motors use what ate known
as PWM (pulse width modulation) amplifiers. These are electronic devices, consisting of
transistors used as switches to rapidly switch on and off the supply in a controlled manner
to control motor speeds. Such drives have higher efficiency.
Sensors and other electronics: The sensors for feedback in robots consists of tachometers
and encoders and potentiometers to sense motor motions, simple switches, force
sensors, acceleration sensors, optical systems, special cameras and vision systems.
Microprocessors & controllers Electronics: There are a host of electronic circuits, motor
controllers, analog to digital converters and digital to analogue converters, frame
grabbers and so on utilized to handle sensors and vision systems and convert the inputs
from them into a form usable by the processor for control of the entire system in
conjunction with the algorithms and software developed specifically for the purpose.
Algorithms and software's (higher level & lower level: The software used consists of
several levels. Motor control software consists of algorithms which help the servo to
move smoothly utilizing the data from feed-back units. At the next level there is software
to plan the trajectory of the end effector and translate the same into commands to
individual motor controllers. The output of sensors is also to be interpreted and
decisions made. At the highest level there is software which accepts commands from
the user of the robot and translates it into appropriate actions at the lower level.
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Q.4. (c) (i)Solution:

Manganese : This is the most common alloying element in all steel. It decreases the
critical temperatures appreciably and thus lets the steel oil harden. Also: it is a cheap
way of increasing the hardenability of steels. It forms a carbide, MnC, but its carbide-
forming tendency is the lowest of all alloying elements. It counteracts the brittleness
caused by sulphur in steels. Equal amounts of manganese and sulphur added in steel
form manganese disulphide readily, which is evenly distributed in it. This greatly
improves the hot-working characteristics and also the lubrication in machining ensuring
good surface finish. Manganese in amounts of 2 to 10% imparts brittleness to steel. The
particular composition of 11 to 14% manganese and 1 to 1.4% carbon has a very high
resistance to wear and abrasion even under high-impact stresses. With such large
manganese content, the critical temperature is reduced and martensite could be obtained
even with slow cooling during quenching. Very rapid quenching allows for retained
austenite thus giving it high ductility and toughness. This is quite useful for service
involving continuous impact loads but not suitable for abrasive loads.
Chromium : It is a strong carbide former and forms complex series of carbide compounds
of chromium and iron. It raises the critical temperature appreciably and thus resists
tempering. It increases hardenability, wear resistance, corrosion and oxidation resistance.
The primary use of chromium in steels, thus is because of its high hardness and corrosion
resistance.
Tungsten : It is a very strong carbide former and forms abrasive-resistant particles in
tool steels. At larger percentages it improves hot hardness and hot strength and as such
is useful in cutting and hot-working tools. It is not softened by tempering. In tungsten
steels, much higher tempering temperatures may be employed with less loss in hardness
with reduction in internal strains compared to plain-carbon steels.
Q.4. (c) (ii)Solution:
Titanium Alloys
Distinctive features: relatively low density, high melting temperatures, and high
strengths are possible.
Limitation: because of chemical reactivity with other materials at elevated temperatures,
these alloys are expensive to refine.
Applications: aircraft structures, space vehicles, and in chemical and petroleum
industries.
Refractory Metals
Distinctive features: extremely high melting temperatures: large elastic moduli,
hardness, and strengths.
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Limitation: some experience rapid oxidation at elevated temperatures.

Applications: extrusion dies, structural parts in space vehicles, incandescent light
filaments, x-ray tubes, and welding electrodes.
Super alloys
Distinctive features: able to withstand high temperatures and oxidizing atmospheres
for long time periods.
Applications: aircraft turbines, nuclear reactors, and petrochemical equipment.
Noble Metals
Distinctive features: highly resistant to oxidation, especially at elevated temperatures;
soft and ductile, limitation expensive.
Applications: jewelry, dental restoration materials, coins, catalysts, and thermocouples.
Section B
Q.5 (a) Solution:
Given: P = 6KW , N = 1500 rpm, ZA = 40, ZB = 80, ZC = 160
dA = mZA = 3(40) = 120 mm
dB = mZB = 3(80) = 240 mm
dC = mZC = 3(160) = 480 mm
d A + dB 120 + 240
Length of arm, D = = = 180 mm
2 2
Tangential component of the gear tooth force on the gear A.
60 × 106 (kW) 60 × 106 × 6

(Mt)A = =
2 πN A 2 π× 1500
= 38197.186 N-mm
2(M t ) A 2 × 38197.186
Pt = = = 636.6197 N
dA 120
Free body diagram of forces.
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Pr
6 2P
Pt t
Pt 4 B
2 Pt
Pr LD
C 5
Pt D
2
Pr
Pr
φ 1
Pt
Torque about the axis O is given by

torque = 2 Pt(LD)
= 2 × (636.6197) × 180
= 229183.092 N-mm
torque = 229.183 N-m Answer
Q.5 (b) Solution:
2P
A double parallel fillet weld of equal legs subjected to a force of 2 P is shown in figure.
The effect of bending is to be neglected. The plane in the weld, where maximum shear
stress is induced,
A
h F D
θ
θ
P t′ C
B E
P h
From triangle ABC,

AB = BC = h (h = size of weld)
∠ECD = 45°
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BC = BE + EC = BE + DE (DE = EC)
= BD cos θ + BD sin θ
BC = BD (cos θ + sin θ)
h = t ′ (cos θ + sin θ)
h
t’ =
cos θ + sin θ
The area of the weld in the plane inclined at angle θ with horizontal is (t ’ l ). Therefore,
the shear stress in this plane is given by,
P P(cos θ + sin θ)
τ = =
(t ′l) hl
dτ
for maximum shear stress = 0
dθ
P
( − sin θ + cos θ) = 0
hl
cos θ = sin θ
θ = 45°
The condition for plane with maximum shear stress is (θ = 45°)
P(sin 45° + cos 45°) P
τmax = = 1.414
hl hl
Q.5.(c) Solution:
Given: m = 260 kg, IE = 0.35 kg-m2, Iw = 1.5 kg-m2, ωE = 5 ωw ,
ωE 90 × 1000
G= = 5, h = 0.6 m, v = = 25 m/s, rw = 0.3 m, R = 50 m
ωw 3600
Let θ = angle of inclination w.r.t. the vertical of a two wheeler
v2
Gyroscopic couple, c 1 = ( 2 I w + GIE ) cos θ
R × rw
( 25 )2
c1 = ( 2 × 1.5 + 5 × 0.35 ) cos θ
50 × 0.3
c 1 = 197.92 cosθ Nm
mv2
Centrifugal couple, c2 = × h cos θ
R
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2
260 × ( 25 )
c2 = × 0.6 cos θ
50
c 2 = 1950 cosθ Nm
Total overturing couple = c1 + c2
c 0 = (197.92 + 1950)cosθ
c 0 = 2147.92cosθ Nm
Balancing couple = mgh sinθ
= 260 × 9.81 × 0.6sinθ = 1530.36sinθ
for equilibrium condition,
Overturing couple = Balancing couple
2147.92cosθ = 1530.36sinθ
tanθ = 1.40354
θ = 54.53° Answer
Q.5 (d) Solution:

At joint D,
Tension in rope, T = W = mg
W
β α
FDE
FCD
W = mg
Resolving forces along horizontal and vertical direction,

ΣF x = 0
W + FDE cos α = FCD cos β
6
cos α = = 0.86377
2 2
3.5 + 6
α = 30.256°
6 1
cos β = = ⇒ β = 45°
62 + 62 2
W + FDE × 0.86377 = FCD × 0.7071 ....(i)
ΣF y = 0
W + FDE × sin 30.256° = FCD × sin 45°
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W + 0.50386 FDE = 0.7071 FCD ...(ii)

Solving equations (i) and (ii)
FCD = 1.4142 W → (compressive)
FDE = 0 N
Force in member CD, BC and AB will be compressive in nature and will be 1.4142 W.
Force in member DE, EF, GF, FC, EC, FB and BG will be zero.
Now at joint A:
FAG
FAB
45° = β
(RA)x
FAG = FAB sin β

FAG = (1.4142 W) sin 45°
FAG = 1 W (Tensile)
Now, (RA)x = FAB cos 45° = (1.4142 W) cos 45°
(RA)x = 1 W
For maximum tensile force, W = 30 kN
mg = 30 × 103 N
m = 3058.1 kg
By maximum compressive force,
1.4142 W = 24 kN
24 × 10 3
mg =
1.4142
24 × 103
m = = 1729.94 kg
1.4142 × 9.81
Hence, the largest value of mass will be 1729.94 kg. Answer
Q.5.(e) Solution:
In a centrifugal governor, the resultant of all the external forces which control the
movement of the ball can be regarded as a single inward radial force acting at the centre
of the ball. The variation of this force F with the radius of rotation of the ball can be
studied under static conditions by measuring the outward radial force on the ball which
is necessary to keep the ball in equilibrium at various configurations (i.e. for different
value of r). The force F is known as the controlling force and is a function of a single
variable r. Thus,
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F = F(r)
Following figure shows a typical plot of the controlling force characteristic curve (AB).
The controlling force is derived from purely statically considerations without reference
to the speed of rotation.
Now, let us suppose that the governor ball rotates at a speed ω. The centripetal force
needed for maintaining the radius of rotation r is given by mω2r, where m is mass of
each ball. The plot of this force against r for a given speed ω will obviously be a straight
line passing through the origin as shown by line OC. So, the equilibrium radius for this
speed ω will be determined by the intersection of the curve AB with the line OC(at the
point D). For this value of r, the controlling force will be equal to the centripetal force.
Mathematically, we can express this equilibrium condition as
F(r) = mω 2r
y B
FC
G
D E
Force, f
r δr
A
tan–1 (mω2 )
O Radius, r x
To determine the condition necessary for stability, let the speed of the governor be ω at
the equilibrium position given by the point D. If the speed remains the same, and if the
dF
radius changes for r + δr, the increment in the controlling force EF will be ⎛⎜ ⎞⎟ δr , and
⎝ dr ⎠
the corresponding increment in the centripetal force EG will be EG = mω2δr.
This restoring force should be greater than zero for the equilibrium position to be
dF
regained. Thus, for stable operation, we get > mω2
dr
dF F
We get finally, >
dr r
The condition for the stability of a governor is that the slope of the curve for the controlling
force should be more than that of the line representing the centripetal force at the speed
considered.
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Q.6 (a) Solution:

Given: W = 250 N, L = 300 mm, D = 200 mm or R = 100 mm; P = 1.2 kW, N = 100 rpm, θ
= 180° = π rad, μ = 0.3, Km = 1.5; Kt = 2, τ = 35 MPa = 35 N/mm2
The shaft pulley arrangement is shown below:
300
200
(T1 + T2 + W)
T1 W T2
All dimensions in mm
We know that torque transmitted by the shaft,

P × 60 1200 × 60
T = = = 114.6 N.m = 114.6 × 103 N-mm
2 πN 2 π × 100
Let, T1 and T2 = Tensions in the tight side and slack side of the belt. respectively (N).
Torque transmitted, T = (T1 − T2 )R
114.6 × 10 3
T1 – T2 = = 1146 N ...(i)
100
⎛T ⎞
We know that 2.3 log ⎜ 1 ⎟ = μθ = 0.3 × π = 0.9426
⎝ T2 ⎠
⎛T ⎞ T
log ⎜ 1 ⎟ = 0.9426 = 0.4098 or 1 = 2.57
⎝ T2 ⎠ 2.3 T2
From equations (i) and (ii), we get
T 1 = 1875.946 N, T2 = 729.94 N
We know that total load (vertical) acting on the pulley,
WT = T1 + T2 + W
= 1875.946 + 729.94 + 250 = 2855.886 N
Bending moment acting on the shaft,
M = WT × L = 2855.886 × 300 = 856.76 × 103 N-mm
Let d = Diameter of the shaft
Equivalent twisting moment, Te = ( K m × M )2 + ( K t × T )2
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= (1.5 × 856.76 × 10 3 )2 + (2 × 114.6 × 10 3 )2
= (10 3 ) (1285.14)2 + (229.2)2

= 1306.89 × 103 N-mm
π
Te = × τ × d3
16
1 1
⎛ 16 × 1306.89 × 10 3 ⎞3
T
d = ⎛⎜ 16 e ⎞⎟ 3=⎜ ⎟
⎝ πτ ⎠ ⎝ π× 35 ⎠
= 57.49 say 60 mm Ans.
Q.6 (b) Solution:

Given: w1 = 5 kN, θ1 = 60°, θ2 = 30°, tan φ = μ, tan φ = 0.4, φ = 21.80°
Maximum value of w2:
For maximum value of w2, the load w2 will be at the point of sliding downward and
load w1 will be at the point of sliding upward.
If the horizontal thrust on link PQ is P.
N1
A
P
P
60°
w1
w1 cos 60°
si n
w1
60
° μ
N1
N1 = w1 cos60 + P sin 60°

P cos 60° = w1 sin 60° + μN1
P cos 60° = w1 sin 60° + tan φ ⋅ w1 cos 60° + tan φ ⋅ P ⋅ sin 60°
P cos 60° – P sin 60° ⋅ tan φ = w1[sin 60° + tan φ ⋅ cos 60°]
P [cos 60° ⋅ cos φ – sin 60° ⋅ sin φ] = w1[sin 60° ⋅ cos φ + sin φ ⋅ cos 60°]
P cos (60° + φ) = w1 sin (60° + φ)
sin(60° + φ)
P = w1 cos(60° + φ)
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sin(60° + 21.8)
P = w1 cos(60° + 21.8)
P = 5 tan 81.8°
= 34.6976 kN
for load w2, P = = w2 tan (α2 – φ)
34.6976 = w2 × tan(30° – 21.8°)
wmax = 240.784 kN Answer
For minimum value of w2:
For minimum value of w2, the load w2 will be at the point of sliding upward and load
w1 will be at the point of sliding downwards.
The horizontal thrust in the link PQ,
P = w1 tan (α1 – φ)
P = 5 × tan (60° – 21.8°)
P = 3.9346 kN
For load w2, P = w2 tan (α2 + φ)
3.9346 = w2 tan (30° + 21.8°)
(w2)min = 3.096 kN Answer
Q.6 (c) Solution:

1
Given: m1 = 100 kg; m2 = 2 kg; l = 80 mm = 0.08 m; ε = ; N = 1000 rpm;
25
1000
or ω = 2π × = 104.7 rad/s
60
Combined stiffness of springs
Let s = Combined stiffness of springs in N/m and
ωn = Natural circular frequency of vibration of the machine
We know that transmissibility ratio (ε)
2 2
1 1
=
(ωn ) = (ωn )
= 2 2
25 ⎛ ω ⎞ ω2 − (ωn ) ( 104.7 )2 − ( ωn )2
⎜ω ⎟ − 1
⎝ n⎠
(104.7) – (ωn) = 25(ωn)2
2 2
(ωn)2 = 421.6
ωn = 20.5 rad/s
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s
We know that ωn = m1
∴ s = m1(ωn)2 = 100 × 421.6 = 42160 N/m

1. Force transmitted to the foundation at 1000 rpm
Let FT = Force transmitted, and
x 1 = Initial amplitude of vibration
Since the damping reduces the amplitude of successive free vibrations by 25%, therefore
final amplitude of vibration,
x 2 = 0.75x1
We know that
⎛x ⎞ a × 2π
log e ⎜ 1 ⎟ = {a = ζωn}
2
⎝ x2 ⎠ (ωn ) − a2
⎛ x1 ⎞ a × 2π
or log e ⎜ ⎟ =
⎝ 0.75x1 ⎠ 421.6 − a 2
Squaring both sides,
a2 × 4 π2
(0.2877)2 =
421.6 − a 2
39.5 a 2 ⎡ ⎛ 1 ⎞ ⎤
or 0.083 = 2 .. ⎢log e ⎜ ⎟ = log e 1.333 = 0.2877 ⎥
421.6 − a ⎣ ⎝ 0.75 ⎠ ⎦
35 – 0.083 a2
= 39.5a2
or a2 = 0.884 or a = 0.94
We know that damping coefficient or damping force per unit velocity,
c = a × 2m1 = 0.94 × 2 × 100 = 188 N/m/s
and critical damping coefficient,
cc = 2 m ωn = 2 × 100 × 20.5 = 4100 N/m/s
∴ Actual value of transmissibility ratio,
⎛ 2c ω ⎞ 2
1+⎜ ⎛ 2 × 188 × 104.7 ⎞
⎟ 1+⎜ ⎟
⎝ cc · ωn ⎠ ⎝ 4100 × 20.5 ⎠
ε= =
2 2 2 2 2 ⎞2
⎛ 2c ω ⎞ ⎛ ω ⎞ ⎛ 2 × 188 × 104.7 ⎞ ⎛ ⎛ 104.7 ⎞
⎜ c · ω ⎟ + ⎜⎜ 1 − ⎟ ⎜ ⎟ + ⎜1−
⎝ 4100 × 20.5 ⎠ ⎜⎝ ⎜⎝ ( 20.5 )2 ⎟ ⎟
⎟
⎝ c n⎠ ⎝ (ωn )2 ⎟
⎠ ⎠ ⎠
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1 + 0.22 1.104
= = = 0.044
0.22 + 629 25.08
We know that the maximum unbalanced force on the machine due to reciprocating
parts,
F = m2 ω2 r = 2(104.7)2(0.08/ 2) = 877 N ...(r = l/2)
∴ Force transmitted to the foundation,
FT = εF = 0.044 × 877 = 38.6 N ...(ε = FT /F )
2. Force transmitted to the foundation at resonance
Since at resonance, ω = ωn, therefore transmissibility ratio,
2 2
⎛ 2c ⎞ ⎛ 2 × 188 ⎞
1+⎜ ⎟ 1+⎜ ⎟
⎝ cc ⎠ ⎝ 4100 ⎠ 1 + 0.0084
ε = = = = 10.92
2 2 0.092
⎛ 2c ⎞ ⎛ 2 × 188 ⎞
⎜c ⎟ ⎜ ⎟
⎝ c⎠ ⎝ 4100 ⎠
and maximum unbalanced force on the machine due to reciprocating parts at resonance
speed ωn,
F = m2(ωn)2 r = 2(20.54)2(0.08/2) = 33.75 N
...(∵ r = l/2)
∴ Force transmitted to the foundation at resonance,
FT = εF = 10.915 × 33.75 = 368.38 N Answer
3. Amplitude of the forced vibration of the machine at resonance
Force transmitted at resonance 368.38
= =
Combined stiffness 42178
= 8.7 × 10–3 m = 8.7 mm Answer
Q.7 (a) Solution:

Given: Mt = 275 N-m, D = 260 mm, d = 180 mm, μ = 0.40, number of pairs = 2, number of
springs = 10, s = 6 mm
(1) Factor of safety against slippage for new clutch
Torque transmitted by one pair,
275
Mt = = 137.5 × 103 N-mm
2
P = 10 × 900 N = 9000 N
When clutch is brand new, uniform pressure theory is applicable,
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μP ( D3 − d 3 )
Mt = 3 ( D2 − d 2 )
0.40 × 9000 ⎛ 260 3 − 1803 ⎞

= ⎜ ⎟ = 400363.6364 N-mm
3 ⎝ 260 2 − 180 2 ⎠
400363.6364
FOS = = 2.91 Answer
137.5 × 10 3
(2) Factor of safety against slippage after initial wear,
We will assume that there is negligible change in spring force after initial wear has
occurred from uniform wear theory,
μP
Mt = (D + d )
4
0.40 × 9000
= (260 + 180) = 396000 N-m
4
396000
FOS = = 2.88 Answer
137.5 × 1000
(3) Wear of friction linning before slippage clutch will slip, when the spring force is no
longer in a position to transmit the engine torque. The spring force required to transmit
the engine torque of 137500 N-mm is given by,
μP
Mt = (D + d )
4
0.40 × P
137500 = × ( 260 + 180 )
4
P = 3125 N
3125
Force per spring = = 312.5 N
10
When force per spring will be less than 312.5 N, the clutch will slip.
Let x is the wear of friction lining
compression of spring = initial compression – x = (6 – x)mm
312.5
Stiffness of spring = N/mm ...(a)
6−x
Initially each spring is compressed by 6mm to give a force of 900 N.
900
Stiffness of spring = N/mm ...(b)
6
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312.5 900
From (a) and (b) =
6−x 6
x = 3.9167 mm Answer
When the wear of friction linning is more than 3.9167 mm, the spring force will be less
than 312.5 N and clutch will slip.
Q.7 (b) Solution:

Given: (pi)f = 50 MPa, R = 90 mm, r = 50 mm, r1 = 75 mm, (Pj)s = 8 MPa
b
For Inner tube, (σr)x = a − 2
x
b
(σh)x = a + 2
x
B
For outer tube, (σr)x = A − 2
x
B
(σh)x = A + 2
x
Case-I: Before the fluid is admitted
For inner tube:
At r = 50 mm, px = 0
At rj = 75 mm, px = 8 MPa
p x = –(σr)x
b
Now, − a = px
x2
b
−a = 0 ⇒ b = 2500 a
(50)2
b 2500 a
Now, −a = 8 ⇒ −a=8
2
75 752
a = –14.4
b = –36000
b ⎛ 36000 ⎞
(σh)50 = a + = −14.4 − ⎜
2 ⎟ = −28.8 MPa
(50) ⎝ 502 ⎠
⎛ 36000 ⎞
(σh)75 = −14.4 − ⎜ ⎟ = −20.8 MPa
⎝ 752 ⎠
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For outer tube:
At R = 90 mm, pR = 0
At rj = 75 mm, prj = 8 MPa
P x = –(σr)x
B
Now, − A = px
90 2
B = 8100 A
B
Now, −A = 8
752
8100 A
−A = 8
752
A = 18.1818
B = 147272.7273
B 147272.7273
Now, (σh)75 = A + = 18.1818 + = 44.3636 MPa
752 752
147272.7273
(σh)90 = 18.1818 + = 36.3636 MPa
90 2
Case-II: After the fluid is admitted:
b
P x = –(σr)x = −a
x2
Condition-I: At R = 90 mm, pR = 0 MPa
Condition-II: At r = 50 mm pr = 50 MPa
b
Now, −a = 0
90 2
b = 8100 a
b
− a = 50
50 2
8100 a
− a = 50 ⇒ a = 22.32
502
8100 × 22.32
Now, (σh)50 = 22.32 +
502
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(σh)50 = 94.6368 MPa

8100 × 22.32
(σh)90 = 22.32 + = 44.64 MPa
902
8100 × 22.32
(σh)75 = 22.32 + = 54.4608 MPa
752
Hoop Stress Inner Tube Inner Tube

(MPa) r = 50 mm rj = 75 mm rj = 75 mm R = 90 mm
Initial –28.8 –20.8 44.3636 36.3636
Due to fluid
94.6368 54.4608 54.4608 44.64
pressure
Final 65.8368 33.6608 98.8244 81.0036
Q.7. (c) Solution:

Minimum Number of Teeth: With reference to figure shown below the maximum value
of the addendum radius of the wheel to avoid interference can be up to BE,
F
Wheel 1 Pinion
2 H
(Driven) D (Driver)
ϕ P
A
B ϕ
G C
E
Base circle
um
e
cl
Pitch circle
cir
cle
Addend
circle
se
ci r
Ba
t ch
Pi
∴ (BE)2 = (BF)2 + (EF)2

= (BF )2 + (FP + PE)2
= (Rcosφ)2 + (Rsinφ + rsinφ)2
= R2cos2φ + R2sin2φ + r2sin2φ + 2Rrsin2 φ
= R2 + r2sin2φ + 2Rrsin2φ
⎡ 1 2 ⎤
= R2 ⎢1 + ( r + 2 Rr )sin 2 φ⎥
2
⎣ R ⎦
⎡ ⎛ 2 ⎞ ⎤
= R 2 ⎢1 + ⎜ ⎛⎜ r ⎞⎟ + 2 r ⎟ sin 2 φ ⎥
⎢ ⎜ R R⎟ ⎥
⎣ ⎝⎝ ⎠ ⎠ ⎦
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r⎛r ⎞ 2
BE = R 1 + ⎜ + 2 ⎟ sin φ
R⎝R ⎠
Therefore, the maximum value of the addendum of the wheel,
aω, max = BE – R
⎡ r r ⎤
= R ⎢ 1 + ⎛⎜ + 2 ⎞⎟ sin 2 φ − 1⎥
⎢⎣ R⎝R ⎠ ⎥⎦
Let t = number of teeth on the pinion

T = number of teeth on the wheel
mT mt T
R = , r= and G = (gear ratio)
2 2 t
mT ⎡ 1⎛1 ⎞ 2 ⎤
a ω, max = ⎢ 1 + ⎜ + 2 ⎟ sin φ − 1⎥
2 ⎢⎣ G⎝G ⎠ ⎥⎦
Let the adopted value of the addendum in same case be aω times the module of teeth.
Then this adopted value of the addendum must be less than the maximum value of the
addendum to avoid interference.
mT ⎡ 1⎛1 ⎞ 2 ⎤
i.e. ⎢ 1 + ⎜ + 2 ⎟ sin φ − 1⎥ ≥ aw m
2 ⎢⎣ G⎝G ⎠ ⎥⎦
2 aw
T≥
⎡ 1⎛ 1 ⎞ 2 ⎤
or ⎢ 1 + ⎜ + 2⎟ sin φ − 1⎥
⎣⎢ G ⎝G ⎠ ⎥⎦
2 aw
In the limiting case, Tmin = ...(1)
1⎛1 ⎞
1 + ⎜ + 2 ⎟ sin 2 φ − 1
G⎝G ⎠
Equation (1) gives the minimum number of teeth on the wheel for the given values of
gear ratio, the pressure angle and the addendum coefficient a ω.
The minimum number of teeth on the pinion is given by
T
t =
G
for aw = 1, i.e. when the addendum is equal to one module,
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2
T ≥
1⎛1 ⎞ 2
1+ ⎜ + 2 ⎟ sin φ − 1
G⎝G ⎠
In case of pinion, the maximum value of the addendum radius to avoid interference is
AF (in Figure),
(AF )2 = (r cosφ)2 + (R sinφ + r sinφ)2
it can be shown that maximum value of the addendum of the pinion is
mt ⎡
ap, max = ⎢ 1 + G(G + 2)sin 2 φ − 1⎤⎥
2 ⎣ ⎦
φ = 20°, T = 48, m = mm, Addendum = 1 m = 8 mm, t = 12
mT 8 × 48
R = = = 192 mm
2 2
mt 8 × 12
r = = = 48 mm
2 2
Ra = R + m = 192 + 8 = 200 mm
2
Ra, max = ( R cos φ)2 + [( R + r ) sin φ]
2
= (192 cos 20° )2 + [(192 + 48 ) sin 20°]
= (180.42 )2 + ( 240 sin 20° )2
Ra, max = 198.2153 mm

The actual value of addendum radius Ra is more than the maximum value Ra, max and
therefore, interference occurs.
Alternate solution:
Path of approach = ( Ra )2 − ( R cos φ)2 − R sin φ
= ( 200 )2 − (192 cos φ)2 − 192 sin φ = 20.63 mm
Maximum length of the path of approach = r sinφ = 48 sin20° = 16.417 mm

As path of approach > Maximum permissible length of the path of approach, so
interference occurs.
The new value of pressure angle can be found be taking Ra, max equal to Ra.
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200 = (192 cos φ )2 + ( 240 sin φ )2

(200)2 = (192)2 cos2φ + (240)2 sin2φ
(200)2 = (192)2 (1 – sin2φ) + (240)2sin2φ
( 200 )2 − (192 )2 3136

sin2φ = 2 2
= = 0.151234
( 240 ) − (192 ) 20736
sinφ = 0.3889
φ = 22.88°
Thus if the pressure angle is increased to 22.88°, the interferene is avoided.
Q.8 (a) Solution:

W
x
A C
B
I
IX
1.5 I
RA = W/2 RB = W/2
L/2 L/2
Central deflection is given by,

L
∂U 1 M x ∂M x
yc = ∂W = E ∫ Ix
×
∂W
⋅ dx
0
Due to symmetry about C,

L /2
2 M x ∂M x
yc =
E ∫ I x ∂W
⋅ dx ...(i)
0
x I 2
Ix = I + (1.5 I − I ) × = I + × ×x
( L / 2) 2 L
⎛ x⎞
Ix = I ⎜ 1 + ⎟ ...(ii)
⎝ L⎠
W ∂M x x
Taking x from A, Mx = ×x, = ...(iii)
2 ∂W 2
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Now, by equations (i), (ii) and (iii)
⎛ Wx ⎞
2 ⎜
L /2 ⎟
⎝ 2 ⎠ × x dx
E ∫ ⎛
yc =
x⎞ 2
0 I ⎜1+ ⎟
⎝ L⎠
L /2
W x2
yc =
2EI ∫ ⎛ x ⎞ dx
0 ⎜1+ ⎟
⎝ L⎠
L /2 ⎛
WL x2 ⎞
yc = 2EI ∫ ⎜
⎝x+L⎠
⎟ dx
0
L /2 ⎡⎛ 2
WL x − L2 ⎞ ⎛ L2 ⎞ ⎤
yc = 2 EI ∫ ⎣⎝ x + L ⎟⎠ + ⎜⎝ x + L ⎟⎠⎦⎥ dx
⎢ ⎜
0
L /2 L /2
WL ⎡ 2 ⎛ 1 ⎞ ⎥
⎤
yc = 2 EI ⎢ ∫
⎢ ( x − L )dx + L ∫ ⎝⎜ x + L ⎠⎟ ⎥
dx
⎣ 0 0 ⎦
⎡ L /2 ⎤
WL ⎢ ⎡ x 2 ⎤ 2 L /2 ⎥
yc = ⎢ − Lx ⎥ + L [ln( x + L)]0
2EI ⎢⎣ ⎣ 2 ⎦0 ⎥⎦
2
WL ⎡⎛ L ⎞ 1 L ⎡ ⎛ 3L ⎞ ⎤⎤
yc = ⎢⎜ ⎟ × − L × + L2 ⎢ ln ⎜ ⎟ − ln L ⎥ ⎥
2 EI ⎣⎝ 2 ⎠ 2 2 ⎣ ⎝ 2 ⎠ ⎦⎦
WL ⎡ L2 − 4L2 3⎤ WL3 ⎡ 3 3⎤
yc = ⎢ + L2 ln ⎥ = ⎢⎣ − 8 + ln 2 ⎥⎦
2 EI ⎣ 8 2⎦ 2 EI
WL3
yc = 0.015232
EI
Castigliano’s Theorem: “If there is any elastic system in equilibrium under the action of
a set of forces W1, W2, W3.............Wn and corresponding displacements y1, y2, y3.............yn
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and a set of moments M1, M2, M3.............Mn and the corresponding rotations θ1, θ2,
θ3.............θn then the partial derivatives of the total strain energy U with respect to anyone
of the forces or moments, taken individually would yield its corresponding
displacements in its direction of action.”
∂U ∂U
y 1 = ∂W and θ1 = ∂M
1 1
L L
M 2 dx ∂U ⎛ ∂M ⎞ dx
Now, U = ∫ 2 EI , y1 = ∂W = ∫ M ⋅ ⎜ ∂W ⎟ ⋅ EI
0 1 0 ⎝ 1⎠
L
∂U ⎛ ∂M ⎞ dx
θ1 = ∂M = ∫ M ⋅ ⎜ ∂M ⎟ ⋅ EI
1 ⎝ 1⎠ 0
Q.8.(b) Solution:
Given: a1 = 0.50 × 10–3 m2, a2 = 1.75 × 10–3 m2, a3 = 6.85 × 10–3 m2, a4 = 0.70 × 10–3 m2,
N1 = 200 rpm, N2 = 196 rpm, R = 1.25 m
Net area of turning moment diagram = a3 – (a1 + a2 + a4)
= [6.85 – (0.5 + 1.75 + 0.7)] × 10–3
= 3.9 × 10–3 m2
Since the energy scale is 1 m2 = 3.5 × 106 Nm, therefore
Net work done per cycle = 3.9 × 10–3 × 3.5 × 106 = 13650 Nm
Work done per cycle is also given as = Tmean × 4π
∴ 13650 = Tmean × 4π
13650
Tmean = FG = = 1086.23 Nm
4π
T max A
ΔE
Turning moment
T mean
D F E
π B G C Line of zero pressure

3π 4π
a1 a2 a4
Crank angle
Suction Expansion Exhaust

Compression
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Work done during expansion stroke = a3 × Energy scale

= 6.85 × 10–3 × 3.5 × 106
= 23975 Nm
Also, Wexpansion = Area of triangle ABC
1 1
= × BC × AG = × π × AG = 1.571 × AG
2 2
1.571 × AG = 23975
AG = 15261 Nm (Tmax)
Excess torque, Texcess = AG – FG
AF = 15261 – 1086.23
AF = 14174.77 Nm
Now from similar triangles ADE and ABC,
DE AF
=
BC AG
AF 14174.77
DE = × BC = × π = 0.9288 π
AG 15261.00
1
Maximum fluctuation of energy, ΔE = × DE × AF
2
1
= × 0.9288 × π × 14174.77 = 20680.36 Nm
2
Let m = mass of rim of a flywheel in kg
N = mean speed of flywheel
N 1 + N 2 200 + 196
= = = 198 rpm
2 2
π2
ΔE = mR 2 N ( N 1 − N 2 )
900
π2 2
ΔE = m × ( 1.25 ) × 198 × 4 = 13.57 m
900
20680.36
Mass of flywheel, m = = 1523.897 kg
13.57
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Q.8 (c) Solution:
1
I = × 300 × 500 3 = 3125 × 106 mm4
12
M 1500 × 106
σmax = y max = × 250 = 120 MPa
I 3125 × 106
(a) Compressive force on the shaded area:
( σ 50 + σ 250 )
Pc = × (200 × 300)
2
⎛ 50 ⎞
⎜ 120 × + 120 ⎟
⎝ 250 ⎠ × 6 × 10 4
=
2
Pc = 4320 kN
Moment of this force about N.A.,
⎡ σmax ⎤
Mc = ⎢ y × IA ⎥
⎣ max ⎦
IA = MOI of the shaded area about the N.A.
1
IA = × 300 × 200 3 + (300 × 200 × 150 2 ) = 1550 × 106 mm4
12
120
Mc = × 1550 × 106 = 744 × 106 N-mm = 744 kN-m
250
(b) Tensile force on the cross-hatched area:
⎛ σ0 + σ150 ⎞
PT = σavg × Area = ⎜ ⎟ × (150 × 120)
⎝ 2 ⎠
⎛ 150 ⎞
⎜ 0 + 120 × 250 ⎟
= ⎜ ⎟ × (150 × 120) = 648 kN
⎝ 2 ⎠
Moment of inertia of hatched portion about N.A.
1
(IA)2 = × 120 × (150)3 + 120 × 150 × 752
12
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(IA)2 = 135 × 106 mm4

Moment of the above force about N.A.
σmax 120
MT = y ( I A )2 = × 135 × 106
max 250
MT = 64.8 × 106 N-mm = 64.8 kN-m
(c) Assumptions:
1. Material is assumed to be homogeneous and isotropic
2. Self weight of the component is neglected
3. The beam is initially straight.
4. Hooke’s law is obeyed at all points.
5. The value of young’s modulus (E) for the material is same in tension and in
compression.
6. Every layer of material is free to expand or contract longitudinally and laterally
under stress, and do not exert pressure upon each other.
7. Plane transverse sections remain plane and normal after bending.
8. The beam has constant cross-sectional area with an axis of symmetry.
Bending stress distribution:
σmax = 120 MPa (C)
250 mm
24 MPa (C)
50 mm
150 mm
250 mm
σ150 = 72 MPa
σmax = 120 MPa (T)

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ESE-2018 Mains Test Series: Mechanical Engineering Test No: 13

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ESE-2018 Mains Test Series: Mechanical Engineering Test No: 13

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Detailed Solutions

ESE-2018 Mechanical Engineering

Q.1 (b) Solution:

Q.1 (c) Solution:

Q.1 (d) Solution:

Year(X1) Demand in 1000 units(y) Deviation of x1 from 2010(x) x2 xy y2

2005 106 –5 25 –530 11236

2006 97 –4 16 –388 9409

2007 85 –3 9 –265 7225

2008 75 –2 4 –150 5625

2009 80 –1 1 –80 6400

2012 60 2 4 120 3600

2013 55 3 9 165 3025

2014 51 4 16 204 2601

2015 47 5 25 235 2209

n = 11 Σy = 793 Σx = 0 Σx2 = 110 Σxy = –624 Σy2 = 60739

Assume best line of fit as,

Q.1.(e) (i) Solution:

Q.2 (a) Solution:

Q.2 (b) Solution:

Die holder Workpiece

Schematic illustration of the coining process

Kickout pin Die

Q.2 (c) Solution:

Examples of Piezoelectric Material

Q.3 (a) Solution:

Q.3 (b) Solution:

Workstation Element Ti Station time Idle time

Cycle time = 10 days

Smoothness index = (Maximum station time − Station time)2

SI = (10 − 10)2 + (10 − 10)2 + (10 − 10)2 + (10 − 8)2 = 2 Answer

– Reduced set-up time

Q.4 (a) Solution:

Make span time = 61

where hatched area shows idle time

Q.4 (b) Solution:

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

Limitation: some experience rapid oxidation at elevated temperatures.

60 × 106 (kW) 60 × 106 × 6

Torque about the axis O is given by

Q.5 (b) Solution:

From triangle ABC,

Let θ = angle of inclination w.r.t. the vertical of a two wheeler

Q.5 (d) Solution:

Resolving forces along horizontal and vertical direction,

W + 0.50386 FDE = 0.7071 FCD ...(ii)

FAG = FAB sin β

Q.6 (a) Solution:

We know that torque transmitted by the shaft,

Equivalent twisting moment, Te = ( K m × M )2 + ( K t × T )2

= (1.5 × 856.76 × 10 3 )2 + (2 × 114.6 × 10 3 )2

= (10 3 ) (1285.14)2 + (229.2)2

Q.6 (b) Solution:

N1 = w1 cos60 + P sin 60°

Q.6 (c) Solution:

∴ s = m1(ωn)2 = 100 × 421.6 = 42160 N/m

Q.7 (a) Solution:

0.40 × 9000 ⎛ 260 3 − 1803 ⎞

Q.7 (b) Solution:

(σh)50 = 94.6368 MPa

Hoop Stress Inner Tube Inner Tube

Initial –28.8 –20.8 44.3636 36.3636

Final 65.8368 33.6608 98.8244 81.0036