1443purl ME ESE-II 1995-1999

ESE
Mechanical Engineering
(Previous Years Solved Papers 1995-1999)
Objectives (Volume-II )
Contents
1. Strength of Materials and Engg. Mechanics ..........................................................1-28
2. Engineering Materials ......................................................................................... 29-42
3. Mechanisms and Machines ................................................................................ 43-73
4. Design of Machine Elements ............................................................................... 74-96
5. Manufacturing Engineering ............................................................................... 97-129
6. Industrial Engineering and Maintenance Engg. ................................................ 130-154

UNIT
I
Strength of Materials
and Engineering Mechanics
Syllabus
Analysis of System of Forces, Friction, Centroid and Centre of Gravity, Dynamics; Stresses and Strains-Compound
Stresses and Strains, Bending Moment and Shear Force Diagrams, Theory of Bending Stresses-Slope and deflection-
Torsion, Thin and thick Cylinders, Spheres.
Contents
Sl. | Topic | Page No.
1. Stress and Strain ................................................................................................................. 2

2. Stress-Strain Relationship and Elastic Constants ................................................................. 5
3. Principal Stresses and Srains and Mohr’s Circle .................................................................. 6
4. Thin Cylinder and Thick Cylinder .......................................................................................... 8
5. Shear Force and Bending Moment Diagrams ..................................................................... 11
6. Bending of Beams, Shear Stress Distribution .................................................................... 17
7. Torsion of Shafts ................................................................................................................ 19
8. Euler’s Theory of Column .................................................................................................... 21
9. Strain Energy and Thermal Stresses .................................................................................. 24
10. Deflection of Beams ........................................................................................................... 25
11. Combined Stresses ........................................................................................................... 27

1 Stress and Strain
1.1 The stretch in a steel rod of circular section, having 1.4 For a composite bar consisting of a bar enclosed
Y
a length L subjected to a tensile load P and inside a tube of another material and when
tapering uniformly from a diameter d1 at one end compressed under a load W as a whole through
to a diameter d2 at the other end, is given by rigid plates at the end of the bar. The equation of
compatibility is given by (suffixes 1 and 2 refer
PLπ
S
(a) PL (b) to bar and tube respectively)
4Ed1d2 Ed1d2
(a) W1 + W2 = W
PLπ 4PL (b) W1 + W2 = Constant
A
(c) (d) [ESE : 1995]
4Ed1d2 πEd1d2
W1 W2
(c) A E = A E
1 1 2 2
1.2 The total extension of the bar loaded as shown in
the figure is
E W1 W2
A = area of cross-section (d) =
A1E 2 A2E1
E = modulus of elasticity
[ESE : 1998]
1.5 A tapering bar (diameter of end sections being,

E
10 T 3T 2T 9T
d1 and d2) and a bar of uniform cross-section ‘d’
10 mm 10 mm 10 mm have the same length and are subjected the same
(a) 10 × 30/AE (b) 26 × 10/AE axial pull. Both the bars will have the same
D
(c) 9 × 30/AE (d) 30 × 22/AE extension if ‘d’ is equal to

[ESE : 1995] d1 + d 2
(a) (b) d1d2
1.3 A bar of uniform cross-section of one sq. cm is 2
A
subjected to a set of five forces as shown in the

d1 + d 2 d1 − d2
given figure, resulting in its equilibrium. That (c) (d)
2 2
maximum tensile stress (in kgf/cm2) produced in
the bar is [ESE : 1998]
M
1.6 The deformation of a bar under its own weight as

1 2 3 4
compared to that when subjected to a direct axial
load equal to its own weight will be
11 kgf 2 kgf 1 kgf 5 kgf 5 kgf
(a) the same (b) one fourth
(c) half (d) double
A B C D E
[ESE : 1998]
1 2 3 4
1.7 A slender bar of 100 mm 2 cross-section is

(a) 1 (b) 2 subjected to loading as shown in the figure below.
(c) 10 (d) 11 If the modulus of elasticity is taken as
[ESE : 1997] 200 × 109 Pa, then the elongation produced in the
bar will be
Strength of Materials and Engineering Mechanics 3
Pin
A
100 kN 200 kN 100 kN
10 mm φ
200 kN 2000 N
w
0.5 m 1.0 m 0.5 m 2000 N
2 mm
(a) 10 mm (b) 5 mm 2 mm
(c) 1 mm (d) nil [ESE : 1998] B
(a) 15 mm (b) 20 mm
1.8 If permissible stress in plates of joint through a
(c) 18 mm (d) 25 mm [ESE : 1999]
pin as shown in the figure is 200 MPa, then the
width w will be
Y
Answers Stress and Strain
1.1 (d) 1.2 (b) 1.3 (d) 1.4 (c) 1.5 (b) 1.6 (c) 1.7 (d) 1.8 (a)
S
Explanations Stress and Strain
1.1 (d) 1.5 (b)
A
Deflection of circular tapering rod subjected to
4P l Pl Pl
tensile load P. is Δl = = =
E πd1d 2 ⎛ πd1d2 ⎞ E × Area
E⎜
δL =
4P L
⎝ 4 ⎟⎠
πd1d2E
E
π π
( )
1.2 (b) 2
∴ Area = de q = d1d2
F.B.D 4 4
10T 10T 9T 9T
1 2 3 ∴ deq = d1d2
7T 7T
E
(δl )total = (δl )1 + (δl )2 + (δl)3 1.6 (c)

P1L1 P2L2 P3L3 Deformation under own weight
= + +
AE AE AE
D
10 × 10 7 × 10 9 × 10
= + +
AE AE AE
26 × 10
=
l
A
AE dx
1.3 (d) x
F.B.D
M
11 11 10 10
consider a small strip ‘dx’ at a distance ‘x’ as
9 9 5 5 shown in figure. We shall find change in length
Maximum tensile force = 11 kg.f for ‘dx’ and then integrate for whole length. Force
exerted by weight below strip ‘dx’
11
Maximum tensile stress = = 11 kgf/cm2 Force (P) = Volume below ‘dx’ × specific weight
1× 1
=Axγ (A = cross – sectional area)
Elongation of the strip
1.4 (c)
(Strain)1 = (Strain)2 (A x γ )d x ⎡ Load = A xρ ⎤
(δl )d x = ⎢Length = d x ⎥
W1 W2 A ×E ⎣ ⎦
∴ =
A1E1 A2E 2
γxd x
(δl )d x =
E
4 ESE-Prelims Mechanical Engineering • Volume-II
For total elongation integrate and take limits Now from Equation (i) and (ii)
l
l γ γ ⎛ x2 ⎞ δl 1
=
δl = ∫0 E xd x = E ⎜⎝ 2 ⎟⎠ δl2 2
0
∴ δl = δl2 / 2
γ l2
δl = ...(i)
2E 1.7 (d)
Now elongation due to load (W) F.B.D.
Wl 100 100 100 100
Y
δl =
AE 100 100
Load = Own weight (given) PL

Total elongation δ =
W = γ lA AE
S
1
∴ A=
W = (100 × 0.5 − 100 × 1 + 100 × 0.5) = 0
AE
γl
A
1.8 (a)
γ l2
∴ (δl )2 = ...(ii) A × σ=F
E
(W – 10) × 2 × 200 = 2000
E ∴ W – 10 = 5
∴ W = 15 mm

E
D
A
M
2 Stress-strain Relationship
and Elastic Constants
2.1 If Poisson’s ratio of a material is 0.5, then the Eμ Eμ

(c) λ = (d) λ =
(1 + μ ) (1 − μ )
Y
elastic modulus for the material is
(a) three times its shear modulus [ESE : 1997]
(b) four times its shear modulus
(c) equal to its shear modulus 2.3 The number of independent elastic constants
S
(d) indeterminate [ESE : 1995] required to express the stress-strain relationship
for a linearly elastic isotropic material is
2.2 The relationship between the Lame’s constant λ, (a) one (b) two
Young’s modulus E and the Poisson’s ratio μ is (c) three (d) four [ESE : 1998]
A
Eμ Eμ
(a) λ = (b) λ = 2.4 The number of elastic constants for a completely
(1 + μ )(1 − 2μ ) (1 + 2μ )(1 − μ ) anisotropic elastic material is
(a) 3 (b) 4
E [ESE : 1999]
(c) 21 (d) 25

Answers Stress-strain Relationship and Elastic Constants

E
2.1 (a) 2.2 (a) 2.3 (b) 2.4 (c)
Explanations Stress-strain Relationship and Elastic Constants

D
2.4 (c)
2.1 (a)
E = 2G (1+ μ) Type of Material Number of Independent
A
put μ = 0.5 elastic constant

∴ E = 2G(1 + 0.5) = 3G 1. Isotropic and 2 (E , ν)
2.3 (b) homogeneous
M
2. Orthotropic 9
By Hooke’s law
3. Anistropic 21
E and μ, Young’s modulus and Poisson’s ratio

3 Principal Stresses and
Strains and Mohr’s Circle
3.1 Match List-I (State of stress) with List-II (Kind of 3. Stress components on any arbitrary place
Y
loading) and select the correct answer using the containing the point
codes given below the lists: Which of these statements are correct?
List-I (a) 1, 2 and 3 (b) 1 and 3
(c) 2 and 3 (d) 1 and 2 [ESE : 1996]
S
3.3 State of stress at a point in a strained body is
A.
shown in figure. Which one of the figure given
below represents correctly the Mohr’s circle for
A
the state of stress?
B. τxy
E
C.
y y
E
(a) (b) x
x
D.
D
List-II y y
1. Combined bending and torsion of circular

shaft. (c) (d)
A
x x
2. Torsion of circular shaft.
3. Thin cylinder subjected to internal pressure.
4. Tie bar subjected to tensile force.
[ESE : 1996]
M
Codes:
A B C D 3.4 Consider the following statements:
(a) 1 2 3 4 State of stress in two dimensions at a point in a
(b) 2 3 4 1 loaded component can be completely specified
(c) 2 4 3 1 by indicating the normal and shear stresses on
(d) 3 4 1 2 1. a plane containing the point
[ESE : 1995] 2. any two planes passing through the point
3. two mutually perpendicular planes passing
3.2 Consider the following statements.
through the point
State of stress at a point when completely
Which of these statements is/are correct?
specified, enables one to determine the
(a) 1 and 3 (b) 2 only
1. Principal stresses at the point
2. Maximum shearing stress at the point (c) 1 only (d) 3 only [ESE : 1998]

Answers Principal Stresses and Strains and Mohr’s Circle
3.1 (c) 3.2 (a) 3.3 (c) 3.4 (d)
Explanations Principal Stresses and Strains and Mohr’s Circle
3.1 (c) 3.2 (a)

Diagram A → Only shear stress is acting i.e. State of stress at a point when completely
circular shaft subjected to torsion. specified, enables one to determine the principal
Diagram B → Only tensile stress is acting i.e. tie stresses at the point, maximum shearing stress
Y
bar is subjected to tensile force. at the point and stress components on any
Diagram C → Hoop stress and longitudinal stress arbitrary plane containing the point.
are acting.
Diagram D → Shear stress as well as normal 3.3 (c)
S
stress is acting therefore circular shaft is Since neither tensile nor compressive stress
subjected to combined bending and torsion. exists, the Mohr’s diagram is simply a circle of
radius τxy and centre at the intersection of the two
A
axis. It can also be verified by transformation of
plane formula.

E
E
D
A
M
4 Thin Cylinder and
Thick Cylinder
4.1 Hoop stress and longitudinal stress in a boiler (a) The circumferential strain will be equal to
shell under internal pressure are 100 MN/m2 and pd ⎛ 1 1 ⎞
Y
⎜ − ⎟
50 MN/m2 respectively. Young’s modulus of 2tE ⎝ 2 m ⎠
elasticity and Poisson’s ratio of the shell material (b) The longitudinal stress will be equal to
are 200 GN/m2 and 0.3 respectively. The hoop pd ⎛ 1 ⎞
⎜⎝ 1 − ⎟
S
strain in boiler shell is 2tE 2m ⎠
(a) 0.425 × 10–3 (b) 0.5 × 10–3
(c) 0.585 × 10–3 (d) 0.75 × 10–3 pd
(c) The longitudinal stress will be equal to
[ESE : 1995] 2t
A
(d) The ratio of the longitudinal strain to
4.2 In a thick cylinder, subjected to internal and
external pressures, let r1 and r2 be the internal m −2
circumferential strain will be equal to
and external radii respectively. Let u be the radial 2m − 1
E
displacement of a material element at radius [ESE : 1998]
r1, r2 > r > r1. Identifying the cylinder axis as z
axis, the radial strain component err is 4.6 A thick-walled hollow cylinder having outside and
(a) u/r (b) u/θ inside radii of 90 mm and 40 mm respectively is
(c) du/dr (d) du/dθ subjected to an external pressure of 800 MNm2.
E
[ESE : 1996] The maximum circumferential stress in the

cylinder will occur at a radius of
4.3 Auto frettage is the method of (a) 40 mm (b) 60 mm
D
(a) joining thick cylinders (c) 65 mm (d) 90 mm [ESE : 1998]

(b) calculating stresses in thick cylinders
4.7 In a thick cylinder pressurized from inside, the
(c) prestressing thick cylinders
hoop stress is maximum at
(d) increasing the life of thick cylinders
(a) The centre of the wall thickness
A
[ESE : 1996]
(b) The outer radius
4.4 From design point of view, spherical pressure (c) The inner radius
vessels are preferred over cylindrical pressure (d) Both the inner and the outer radii
M
vessels because they [ESE : 1998]

(a) are cost effective in fabrication
(b) have uniform higher circumferential stress 4.8 Circumferential stress in a cylindrical steel boiler
(c) uniform lower circumferential stress shell under internal pressure is 80 MPa. Young’s
(d) have a larger volume for the same quantity of modulus of elasticity and Poisson’s ratio are
material used respectively 2×105 MPa and 0.28. The magnitude
[ESE : 1997] of circumferential strain in the boiler shall be
(a) 3.44 × 10–4 (b) 3.84 × 10–4
4.5 When a thin cylinder of diameter ‘d’ and thickness (c) 4 × 10–4 (d) 4.56 × 10–4
‘t’ is pressurized with an internal pressure of ‘p’ [ESE : 1999]
(1/m is the Poisson’s ratio and E is the modulus
of elasticity), then out of the following, which 4.9 A thin cylinder with closed lids is subjected to
statement is correct internal pressure and supported at the ends as
shown in figure-I.
4.10 A thin cylinder with both ends closed is subjected

to internal pressure p. The longitudinal stress at
X X the surface has been calculated as σo. Maximum
shear stress at the surface will be equal to
Figure-I
(a) 2σ0 (b) 1.5σ0
The state of stress at point X is as
(c) σ0 (d) None of these
represented as
[ESE : 1999]
4.11 If a thick cylindrical shell is subjected to internal

pressure, then hoop stress, radial stress and
Y
(a) (b) longitudinal stress at point in the thickness will be
(a) Tensile, compressive and compressive
respectively
S
(b) All compressive
(c) All tensile
(d) Tensile, compressive and tensile respectively
(c) (d)
[ESE : 1999]
[ESE : 1999]
A
Answers Thin Cylinder and Thick Cylinder

E
4.1 (a) 4.2 (c) 4.3 (c) 4.4 (c) 4.5 (d) 4.6 (a) 4.7 (c) 4.8 (a) 4.9 (a)
4.10 (c) 4.11 (d)

E
Explanations Thin Cylinder and Thick Cylinder
4.1 (a) 4.3 (c)

pd Autofrettage: Autofrettage is one of the oldest
D
= 100N / mm2
σ1 =
2t methods of prestressing (method of increasing
pd pressure capacity) the cylinders. It is overloading
σ2 = = 50N/mm2
4t the cylinder before it is put into service. In this
A
pd method, a forged cylinder is subjected to a large

Hoop strain = (2 − μ)
4tE internal pressure, so as to expand the internal
50 diameter, causing overstrain. The internal
= × (2 − 0.3) = 0.425 × 10–3
200 × 1000 pressure is applied is such a way that a portion
M
of the cylinder at the inner surface is subjected

4.2 (c)
to stresses in the plastic range, while the outer
c′ surface is still in the elastic range.
b′
b c u+δ When the pressure is released, the portion of the
u
d′ cylinder at the outer surface contracts exerting
δx a′
a d u
the pressure on the portion at the inner surface
which has undergone permanent deformation. As
x
a result, residual compressive stresses are
induced at the inner surface and tensile stresses
O at the outer surface.
Change in displacement = u + δu – u = δu
It is commonly used is gun barrels. It not only
δu du
∴ Radial strain, ∈r = Lt = increases the pressure capacity of the cylinder,
δx → 0 δ x dr
but also improves the endurance strength..
4.4 (c) 4.8 (a)

In spherical vessel, the circumferential stress and
pd
longitudinal stress is equal and less than Circumferential stress, σ1 = = 80 N / mm2
2t
circumferential stress of cylinder vessel.
σh =
pd pd ⎛ μ ⎞
(for cylinder) Circumferential strain = ⎜ 1 − ⎟⎠
2t 2Et ⎝ 2
pd
σh = (for sphere)
4t 80 ⎛ 0.28 ⎞
= ⎜1 − ⎟ = 3.44 ×10–4
2 × 105 ⎝ 2 ⎠
Y
4.5 (d)
pd 4.9 (a)
Circumferential stress (σ1) =
2t Point ‘x’ is subjected to circumferential and
S
pd longitudinal stress. i.e. tension in all faces, but
Longitudinal stress (σ2 ) =
4t there is no shear stress.
Circumferential strain
4.10 (c)
A
δd σ1 1 pd pd 1 pd
e1 = = − . = − .
d E m 4tE 2tE m 4tE pd
Longitudinal stress ( σ2 ) = = σ0
4t
pd ⎛ 1 ⎞
e1 = ⎜⎝ 1 − ⎟
2tE 2m ⎠
E pd
Hoop stress ( σ1 ) = = 2σO
Longitudinal strain 2t
δl σ2 1 σ1 pd 1 pd Principal stresses 2σ0, σ0

e2 = = − , = − ,
l E m E 4tE m 2tE 2σ0
Shear stress = = σ0
E
2
pd ⎛ 1 1 ⎞
e2 = ⎜ − ⎟
2tE ⎝ 2 m ⎠
4.11 (d)
D
1 1
Longitudinal Strain − m −2
= 2 m =
Circumfential Strain 1 2m −1 σh(max)
1−
2m
A
σh(min)
P
4.6 (a)
The maximum hoop stress will always occurs at σr
M
inner most radii irrespective of the location of

pressure
4.7 (c)
A
Hoop stress: σ x = +B
r2
Hence hoop stress will be maximum at inner
radius
5 Shear Force and Bending
Moment Diagrams
5.1 Constant bending moment over span ‘l’ will occur Which of these statements are correct?
(a) 1 and 3 (b) 1 and 2
Y
in
W (c) 2 and 3 (d) 1, 2 and 3
[ESE : 1995]
(a)
l 5.4 A cantilever beam having 5 m length is so loaded
S
W that it develops a shearing force of 20 T and a
bending moment of 20 T-m at a section 2 m from
(b) the free end. Maximum shearing force and
A
l maximum bending moment developed in the
W beam under this load, are respectively 50 T and
125 T-m. The load on the beam is
(c)
(a) 25 T concentrated load at free end
l
E (b) 20 T concentrated load at free end
W W
(c) 5 T concentrated load at free end 2 T/m load
(d) over entire length
(d) 10 T/m udl over entire length [ESE : 1995]
l1 l l1
E
[ESE : 1995] 5.5 The bending moment (M) is constant over a length
segment (l) of a beam the shearing force will also
5.2 The given figure shows a beam BC simply
be constant over this length and is given by
supported at C and hinged at B (free end) a
(a) M/l (b) M/2l
D
cantilever AB. The beam and the cantilever carry

(c) M/4l (d) None of the above
forces of 100 kg) and 200 kg respectively. The
[ESE : 1996]
bending moment at B is
200 kg 100 kg 5.6 If the shear force acting at every section of a beam
A
is of the same magnitude and of the same

A B C
direction then it represents a
(a) simply supported beam with a concentrated
1m 1m 1m 1m
load at the centre
M
(a) Zero (b) 100 kg-m (b) overhung beam having equal overhung at both
(c) 150 kg-m (d) 200 kg-m supports and carrying equal concentrated
[ESE : 1995] loads acting in the same direction at the free
5.3 Consider the following statements: ends
If at a section distant from one of the ends of the (c) cantilever subjected to concentrated load at
beam, M represents the bending moment V the the free end
shear force and w the intensity of loading, then (d) simply supported beam having concentrated
1. dM/d x = V loads of equal magnitude and in the same
2. dV/d x = w direction acting at equal distances from the
3. dw/d x = y supports
y - the deflection of the beam at the section [ESE : 1996]
5.7 A cantilever beam carries a load W uniformly 5.11 The maximum bending moment in a simply
distributed over its entire length. If the same load supported beam of length L loaded by a
is placed at the free end of the same cantilever, concentrated load W at the midpoint is given by
then the ratio of maximum deflection in the first WL
case to that in the second case will be (a) WL (b)
2
(a) 3/8 (b) 8/3
WL WL
(c) 5/8 (d) 8/5 [ESE : 1996] (c) (d)
4 8
5.8 The given figure shows a cantilever of span L [ESE : 1996]
subjected to a concentrated load P and a moment
5.12 A beam, built in both ends, carries a uniformly
Y
M at the free end. Deflection at the free end is
distributed load over its entire span as shown in
given by
P
figure-I. Which one of the diagrams given below
represents bending moment distribution along the
S
M length of the beam?
L
UDL
2 2
PL ML ML2 PL3
(a) + (b) +
2E I 3E I 2E I 3E I
A
Figure-I
ML2 PL3 ML2 PL3
(c) + (d) +
3E I 2E I 2E I 48E I
[ESE : 1996] (a)
E
5.9 For a cantilever beam of length ‘L’ flexural rigidity
EI and loaded at its free end by a concentrated
load W, match List-I with List-II and select the
(b)
correct answer using the codes below the lists:
E
List-I List-II
A. Maximum bending 1. WL
moment (c)
B. Strain energy 2. WL2/2EI
D
C. Maximum slope 3. WL3/3EI

D. Maximum deflection 4. W2L3/6EI
(d)
Codes:
A
A B C D
[ESE : 1996]
(a) 1 4 3 2
(b) 1 4 2 3 5.13 A beam subjected to a load P is shown in the
(c) 4 2 1 3 figure below.
M
(d) 4 3 1 2 [ESE : 1996]

L/2 L/2
5.10 The given figure shows the shear force diagram A B
for the beam ABCD bending moment in the portion
BC of the beam
L/2
C D
A B D
C
P
(a) is a non zero constant
(b) is zero The bending moment at the support A of the beam
(c) varies linearly form B to C will be
(d) varies parabolically from B to C (a) PL (b) PL/2
[ESE : 1996] (c) 2PL (d) Zero [ESE : 1997]
5.14 A 2 m long beam BC carries a single concentrated W 2W W

load at its mid-span and is simply supported at
ends by two cantilevers AB, 1 m long and CD,
2 m long as shown in the figure.
C C C C
100 kgf
The maximum shear force in the beam will be
(a) Zero (b) W
A B C D (c) 2W (d) 4 W [ESE : 1998]
1m 2m 2m 5.19 A lever is supported on two hinges at A and C. It
Y
The shear force at end A of the cantilever AB will carries a force of 3 kN as shown in the figure below.
be The bending moment at B will be
(a) zero (b) 40 kgf 3 kN
(c) 50 kgf (d) 60 kgf [ESE : 1997]
S
1m
5.15 If a beam is subject to a constant bending
A B C
moment along its length then the shear force will
A
(a) also have a constant value everywhere along
its length 1m 1m 1m
(b) be zero at all sections along the beam (a) 3 kN-m (b) 2 kN-m
(c) be maximum at the centre and zero at the (c) 1 kN-m (d) Zero [ESE : 1998]
ends
E
5.20 The bending moment diagram shown in figure-I
(d) zero at the centre and maximum at the ends
corresponds to the shear force diagram in
[ESE : 1997]
5.16 A simply supported beam with width ‘b’ and depth

E
‘d’ carries a central load W and undergoes
deflection δ at the centre. If the width and depth
and interchanged, the deflection at the centre of
Figure-I
the beam would attain the value
D
(a)
2
⎛d⎞ ⎛ d⎞
(a) ⎜⎝ ⎟⎠ δ (b) ⎜ ⎟ δ (b)
b ⎝ b⎠
3 3/2
⎛ d⎞ ⎛ d⎞
A
(c)
(c) ⎜ ⎟ δ (d) ⎜ ⎟ δ
⎝ b⎠ ⎝ b⎠
[ESE : 1997]
5.17 For the beam shown in the figure below, the elastic
M
curve between the supports B and C will be

(d) [ESE : 1999]
P P
B C
5.21 Which one of the following portions of the loaded
a 2b a beam shown in the given figure is subjected to
pure bending?
(a) circular (b) parabolic
W W
(c) elliptic (d) a straight line
A E
B C D
[ESE : 1998]
L L L L
5.18 A simply supported beam is loaded as shown in
(a) AB (b) DE
the figure below.
(c) AE (d) BD
[ESE : 1999]

Answers Shear Force and Bending Moment Diagrams
5.1 (d) 5.2 (a) 5.3 (b) 5.4 (d) 5.5 (d) 5.6 (c) 5.7 (a) 5.8 (b) 5.9 (b)
5.10 (a) 5.11 (c) 5.12 (d) 5.13 (b) 5.14 (c) 5.15 (b) 5.16 (b) 5.17 (a) 5.18 (c)
5.19 (c) 5.20 (b) 5.21 (d)
Explanations Shear Force and Bending Moment Diagrams
5.1 (d) For similar triangle
Y
Bending moment diagram for loading given in 50T F F
= =
option (d) 5 x 2
∴ F = 20T
W W
M at 2 m from free end.
S
= 10T × 2 × 1 = 20T m
10T m udl over whole span of beam
l1 l l1
5.5 (d)
A
BMD dM
= Sx
dx
When bending moment is constant then shearing
5.2 (a)
E force in that section is zero.
Bending moment at internal hinge is always zero.
5.6 (c)
5.3 (b)
W
Rate of change of bending moment is equal to
E
the shear force at that section i.e
l
dM
=V W + W
dx
D
Rate of change of shear force is equal to the SFD
intensity of loading
5.7 (a)
dV
WL3
A
= –W
dx In first case δ1 =
8E I
5.4 (d) WL3
In second case δ2 =
3E I
M
10T/m
δ1 3
B
∴ =
M A δ2 8
RA 5m 5.8 (b)
RA = 10 × 5 = 50T Deflection can be found by using super imposition
5 method. Deflection due to point load (cantilever)
M = 10 × 5 × = 125T.m
2 Pl 3
S.F diagram δ1 = Deflection due to moment at end in
3E I
Ml 2
50 T cantilever δ2 = . Summation of δ1 and δ2 will
F 2E I
2m give the total deflection of the cantilever.
5m
5.9 (b) 5.12 (d)

Strain energy stored in cantilever under
M M
concentrated load at free end.
2 2
lM dx l (W x) d x R1 R2
u=∫ =∫
0 2E I 0 2E I
nd
2 Degree
W 2l 3
u=
6E I
Maximum bending moment B.M.Diagram
Y
at fixed end = WL
x W
5.13 (b)
l x
S
x A
2
Wl
Maximum slope =
2E I
A
Wl 3
Maximum deflection =
3E I A + PL/2
PL/2 –
+ PL/2
5.10 (a)
E
+ PL/2
W W BMD
+ C D
A B – 5.14 (c)
SFD W Loading W
F.B.D.
E
diagram
50 kgf
100 kgf
+
A
D
A B C D B
BMD B C
50 kgf
5.11 (c) 50 kgf 50 kgf
A
W
5.15 (b)
A C
B
dM
=S
dx
M
R1= W R2= W
2 2 Whenever Bending moment is constant then shear
W L WL force will be zero.
Bending moment at B = × =
2 2 4
5.16 (b)
WL For simple supported beam
4
WL3
deflection: δ =
48E I
B.M. Diagram 1 δ1 I
for same load; δ ∝ , = I
I δ 1
bd 3
δ= ⋅ δ1
db3
1 1 5.19 (c)
∴ δ× bd 3 = δ1 × b 3d
12 12 3 kN
2 1m
⎛d ⎞ 3 kN 3 kN
∴ δ1 = ⎜ ⎟ δ
⎝ b⎠ D
3 kN 3 kN-m
5.17 (a) D
From symmetry, 1 kN
1 kN
1 kN-m
Reaction at support B and C will be same and +2
A
Y
equal to P (upward). B C
Taking moment about B,
–1
P × a + RC × 2b = P × (a + 2b)
P × 2b 5.20 (b)
S
RC = =P
2b Since B.M.D. is of first degree thus corresponding
RB = 2P – P S.F.D will be of zeroth degree.
P P
A
A B C D
RB RC
a 2b a
5.21 (d)
S.F. diagram
P P
+Ve Shear force diagram.
E W
–Ve
P P
B.M. diagram
–Ve A B C D
E
Pa Pa
∵ SF = 0 ⇒ BM = constant
–W
Elastic curve will be circular. In section BD, shear force is zero. As we know
D
⎡ EI ⎤ dM
⎢⎣R = M = constant⎥⎦ that s =
dX
∴ M = Constant
5.18 (c)
A
Hence this section subjected to pure bending.

W 2W W
A B
R1 R1
M
Moment about A = 0
W × c + 2W × 2c + W × 3c – R2 × 4c = 0
R2 = 2W = R1
2W
B
A
–W
SFD –2W
6 Bending of Beams,
Shear Stress Distribution
6.1 A rectangular section beam subjected to a 6.4 A beam cross-section is used in two different
Y
bending moment M varying along its length is orientations as shown in the figure given below:
required to develop same maximum bending
stress at any cross-section. If the depth of the
b/2
section is constant, then its width will vary as
S
(a) M (b) b
M
(c) M 2 (d) 1/M b/2 b
[ESE : 1995]
A
6.2 In a beam of circular cross-section, the shear (A)
stress variation across a cross-section is (B)

E
Bending moments applied to the beam in both
cases are same. The maximum bending stresses
(a) (b)
induced in cases (A) and (B) are related as
(a) σA = σB (b) σA = 2σB
E
σB σB
(c) σ A = (d) σ A =
2 4
[ESE : 1997]
D
(c) (d)
6.5 Two beams of equal cross-section area are
subjected to equal bending moment. If one beam
has square cross-section and the other has circular
A
[ESE : 1995]
section, then
6.3 A wooden beam of rectangular cross-section (a) both beams will be equally strong
10 cm deep by 5 cm wide carries maximum shear (b) circular section beam will be stronger
force of 2000 kgf. Shear stress at neutral axis of
M
(c) square section beam will be stronger

the beam section is (d) the strength of the beam will depend on the
(a) zero (b) 40 kgf/cm2 nature of loading
(c) 60 kgf/cm 2 (d) 80 kgf/cm2 [ESE : 1999]
[ESE : 1997]

Answers Bending of Beams, Shear Stress Distribution
6.1 (a) 6.2 (a) 6.3 (c) 6.4 (b) 6.5 (c)
Explanations Bending of Beams, Shear Stress Distribution
6.1 (a) 24M

∴ σA =
b3
For second case
b
h 1 ⎛ b⎞ b4
× ⎜ ⎟ × (b ) =
3
IB =
12 ⎝ 2 ⎠ 12 × 2
M σB
∴ =
Y
b4 b
12 × 2 2
M σb
= y 12M
I max ∴ σB =
S
M σb b3
=
1 h ∴ σ A = 2σB
bh 3
12 2
A
1 2 6.5 (c)
∴ M = σb × bh
6
Width (b) ∝ M If ‘d’ is diameter of circular section and ‘a’ be the
side of square section and cross-section area of
6.2 (a)
E sqaure is equal to cross area of circle.
Shear stress in circular cross-section
π 2
F 2 ∴ a2 = d
τ= (r − y 2 ) 4
3I
π
τ=0 ∴ a= d
E
4
y Section modulus:
τmax
a3 π
, zc = d3
D
zs =
6 32
τ=0
zs a3 32 π π 32
= × = × ×
zc d 3
π×6 4 4 π×6
A
6.3 (c)
= 1.18
3 S Hence square section beam will be stronger than
τmax = τNA = 1.5 τavg = ⋅
2 bd circular beam.
M
3 2000
τmax = × = 60 kg.f/cm2
2 10 × 5
6.4 (b)
For first case
3
1 ⎛ b⎞ b4
IA = ×b× ⎜ ⎟ =
12 ⎝ 2⎠ 12 × 8
M σ M × 12 × 8 σ
= ⇒ = A
IA y b 4 b/4
7 Torsion of Shafts
7.1 A 3-meter long steel cylindrical shaft is rigidly respectively is also twisted through the same
Y
held at its two ends. A pulley is mounted on the angle of twist θ. The value of maximum shear in
shaft at 1 meter from one end; the shaft is twisted the hollow shaft will be
by applying torque on the pulley.
16 8
The maximum shearing stresses developed in 1 m (a) τ (b) τ
S
15 7
and 2 m lengths are respectively τ1 and τ2. The
ratio τ2 : τ1 is 4
(c) τ (d) τ
(a) 1/2 (b) 1 3
A
[ESE : 1997]
(c) 2 (d) 4
[ESE : 1995] 7.4 Two hollow shafts of the same material have the
same length and outside diameter. Shaft 1 has
7.2 A round shaft of diameter ‘d’ and length ‘l’ fixed
E
at both ends ‘A’ and ‘B’, is subjected to a twisting
internal diameter equal to one third of the outer
diameter and shaft 2 has internal diameter equal
moment ‘T’ at ‘C’ at a distance of 1/4 from A (see
to half of the outer diameter. If both the shafts are
figure). The torsional stresses in the parts AC and
subjected to the same torque, the ratio of their
CB will be
twists θ1/θ2 will be equal to
T
E
A B (a) 16/81 (b) 8/27
C (c) 19/27 (d) 243/256
L/4
[ESE : 1998]
L
D
(a) equal 7.5 A solid shaft of diameter 100 mm, length 1000 mm
is subjected to a twisting moment ‘ T ’, the
(b) in the ratio of 1 : 3
maximum shear stress developed in the shaft is
(c) in the ratio of 3 : 1
60 N/mm2. A hole of 50 mm diameter is now drilled
A
(d) indeterminate
throughout the length of the shaft. To develop a
[ESE : 1997]
maximum shear stress of 60 N/mm2 in the hollow
7.3 Maximum shear stress in a solid shaft of diameter shaft, the torque ‘T’ must be reduced by
M
D and length L twisted through an angle θ is τ. A (a) T/4 (b) T/8

hollow shaft of same material and length having (c) T/12 (d) T/16 [ESE : 1998]
outside and inside diameters of D and D /2

Answers Torsion of Shafts
7.1 (a) 7.2 (c) 7.3 (d) 7.4 (d) 7.5 (d)
Explanations Torsion of Shafts
7.1 (a) for same torque, and identical shaft
Angle of twist is same θ∝ 1

J
τ Gθ
= (torsion formula) For first shaft.
R L
π
⎡
( )
4⎤ 80 π 4
∴ τ × L = constant J1 = × ⎢D4 − D
τ1 × 1 = τ2 × 2 32 ⎣ 3 ⎥⎦ = 81 × 32 D
τ2 1 for second shaft
Y
τ1 = 2 π ⎡
( )
4⎤ 15 π 4
J2 = × ⎢D4 − D ⎥⎦ = 16 × 32 D
32 ⎣ 2
7.2 (c) ∴ θ1J1 = θ2J2
τ Gθ θ1 15 81 243
S
= = × =
d L θ2 16 80 256
2
for same angle of twist 7.5 (d)
A
1
τ∝ For solid shaft
L
l 3l 16T
∴ τ1 × = τ2 × τ= ...(i)
πd 3
4 4
E
τ1 3 For hollow shaft
∴ =
τ2 1
16 16T
τ= × ...(ii)
7.3 (d) 15 πd 3
From eq (i) and eq (ii),
E
For solid shaft
τ Gθ Gθ D 15
= ∴ τ= . T′ = T
D/2 L L 2 16
for hollow shaft
D
τ2 Gθ Gθ D 15 T
= ∴ τ2 = . =τ Hence reduced torque = T − T=
D/2 L L 2 16 16

A
7.4 (d)
We know that
T Gθ
=
M
J L
8 Euler’s Theory of Column
8.1 Match List-I (End conditions of columns) with P

Dotted
A
Y
List-II (Lowest critical load) and select the correct portion A
D E
answer using the codes given below the lists: F
List-I B1 B
A. Column with both ends hinged
S
B. Column with both ends fixed
C. Column with one ends fixed and the other end R1 R2 R3 R4
A
hinged C
D. Column with one ends fixed and the other O l V

k
end free
List-I List-II
List-II
E
A. R1 1. Long, stable
1. π2E I / L2
B. R2 2. Short
2. 2π2E I/ L2 C. R3 3. Medium
D. R4 4 . Long, unstable
E
3. 4π2E I/ L2
Codes:
2 2
4. π E I/ 4L A B C D
(E is the Young’s modulus of elasticity of column (a) 2 4 3 1
D
material, L is the length and I is the second (b) 2 3 1 4

moment of area of cross-section of the column.) (c) 1 2 4 3
Codes: (d) 2 1 3 4 [ESE : 1997]

A
A B C D 8.3 The ratio of the compressive critical load for a

(a) 1 2 3 4 long column fixed at both the ends and a column
(b) 3 2 1 4 with one end fixed and the other end free is
M
(c) 1 3 2 4 (a) 1 : 2 (b) 1 : 4

(d) 2 4 3 1 [ESE : 1995] (c) 1 : 8 (d) 1 : 16
[ESE : 1997]
8.2 The curve ABC is the Euler’s curve for stability of
column. The horizontal line DEF is the strength 8.4 The Euler’s crippling load for a 2 m long slender
limit. With reference to this figure match List-I steel rod of uniform cross-section hinged at both
(Regions) with List-II (Column specifications) and the ends is 1 kN. The Euler’s crippling load for a
select the correct answer using the codes given 1 m long steel rod of the same cross-section and
below the lists: hinged at both ends will be
(a) 0.25 kN (b) 0.5 kN
(c) 2 kN (d) 4 kN [ESE : 1998]
8.5 Euler’s formula gives 5 to 10% error in crippling 8.6 A short column of external diameter D and internal
load as compared to experimental results in diameter d carries an eccentric load W. The
greatest eccentricity which the load can be applied
practice because
without producing tension on the cross-section of
(a) effect of direct stress is neglected
the column would be
(b) pin joints are not free from friction
(c) the assumptions made in using the formula D +d D2 + d2
(a) (b)
are not met in practice 8 8d
(d) the material does not behave in an ideal
elastic way in tension and compression D2 + d2 D2 + d2
(c) (d)
Y
[ESE : 1998] 8D 8
[ESE : 1999]

S
Answers Euler’s Theory of Column
8.1 (c) 8.2 (b) 8.3 (d) 8.4 (d) 8.5 (c) 8.6 (c)
Explanations Euler’s Theory of Column
8.1 (c)
A 8.2 (b)
E
π 2E I Strength limit
Critical load PE =
L2eq
Column with both ends pinned, leq = l inelastic stability limit
σ0
E
π 2E I Elastic stability limit
∴ PE = 2 Long stable column
l
Column with both ends fixed; leq = l/2 Long unstable column
D
2 Intermediates columns
4π E I
∴ PE = Short columns
l2
Column with one end fixed and other end hinged leq
k
A
l
leq =
2 8.3 (d)
2 π 2E I π 2E I
∴ PE = PE =
M
l2 L2eq
Column with one end fixed and other end free
leq = 2l 4 π 2E I
P1 = → both end fixed
2 l2
π EI
∴ PE =
4l 2 π 2E I
P2 = → one end fixed and other free
4l 2
P1
∴
P2 = 16 : 1
So, best possible answer is (d).
8.4 (d) π 3
and Z = D (1 − K 4 )
32
π 2E I
PE = for both ends hinged d
l2 where K =
D
π2E I W
∴ 1000 = ...(i)
4 W.e
2
π EI
PE = (at l = 1m ) –σa + σb σa – σb
1
Y
∴ PE = 4 kN
W.e
8.6 (c)
To avoid tension on cross-section column W
S
∴ σa + σb ≤ 0 d
W We
⇒ − + = 0 ...(i)
A Z D
A
π 2
⇒ A = (D − d 2 ) But these value in equation (i)
4
D2 + d2
We have, e ≤
8D
E

E
D
A
M
9 Strain Energy &
Thermal Stresses
9.1 A 10 cm long and 5 cm diameter steel rod fits

2τ2 τ2
(1+ ν) (2 + ν)
Y
snugly between two rigid walls 10 cm apart at (c) (d)
E 2E
room temperature. Young’s modulus of elasticity
and coefficient of linear expansion of steel are [ESE : 1998]
2×106 kgf /cm2 and 12×10–6/°C respectively. The 9.3 If the rigid rod fitted snugly between the supports
S
stress developed in the rod due to a 100°C rise in as shown in the figure below, is heated, the stress
temperature will be induced in it due to 20°C rise in temperature will
(a) 6 × 10–10 kgf/cm2 (b) 6 × 10–9 kgf/cm2 be (α = 12.5 × 10–6/°C and E = 200 GPa)
(c) 2.4 × 103 kgf/cm2 (d) 2.4 × 104 kgf/cm2
A
10 mm φ
[ESE : 1997]
9.2 For the state of stress of pure shear τ, the shear

strain energy stored per unit volume in the elastic,
E 0.5 m
k = 50 kN/m
homogenous isotropic material having elastic
constants E and ν will be (a) 0.07945 MPa (b) –0.07945 MPa
(c) –0.03972 MPa (d) 0.03972 MPa
τ2 τ2
(a) (1+ ν) (b) (1+ ν) [ESE : 1999]
E 2E
E

Answers Strain Energy & Thermal Stresses

D
9.1 (c) 9.2 (a) 9.3 (b)
Explanations Strain Energy & Thermal Stresses

A
9.1 (c) 9.2 (a)
Strain energy due to pure shear

1 τ2 τ2
M
1
(U ) = φ×τ = × =
φ 5 cm
2 2 G 2G
l = 10 cm τ2
U= (1+ μ ) [E = 2G(1+ μ)]
E = 2 × 106 kgf / cm2 E
α = 12 × 10−6 / °C ; ΔT = 100°C 9.3 (b)

It is statically indeterminate. So we used one
αTE
equation of compatibility. σ= = 0.07945
AE
PL 1+
L α ΔT = kL
AE
σ = E α ΔT = 12 × 10−6 × 2 × 106 × 100

= 2.4 × 103 kgf/cm2
10 Deflection of Beams
10.1 A beam having uniform cross-section carries a 1 1

(a) θ (b) θ
Y
uniformly distributed load of intensity ‘q’ per unit 3 2
length over its entire span, and its mid-span
2
deflection is δ. (c) θ (d) θ
3
The value of mid-span deflection of the same [ESE : 1997]
S
beam when the same load is distributed with
10.4 A simply supported beam of constant flexural
intensity varying from 2q per unit length at one
rigidity and length 2L carries a concentrated load
end to zero at the other end is
P at its mid-span and the deflection under the
A
δ δ
(a) (b) load is δ. If a cantilever beam of the same flexural
3 2
rigidity and length L is subjected to a load P at
2δ
(c) (d) δ [ESE : 1995] its free end, then the deflection at the free end
3
E will be
10.2 A simply supported beam carrying a concentrated (a) δ/2 (b) δ
load W at mid-span deflects δ1 under the load. If (c) 2 δ (d) 4 δ [ESE : 1998]
the same beam carries the load W such that it is
distributed uniformly over entire length and 10.5 A cantilever beam of rectangular cross-section is
undergoes a deflection δ2 at the mid span. The subjected to a load W at its free end. If the depth
E
ratio δ1: δ2 is of the beam is doubled and the load is halved,

the deflection of the free end as compared to
(a) 2 : 1 (b) 2 : 1
original deflection will be
(c) 1 : 1 (d) 1 : 2 [ESE : 1995]
D
(a) half (b) one-eighth

10.3 Two identical cantilevers are loaded as shown in (c) one-sixteenth (d) double
the respective figures. If slope at the free end of [ESE : 1999]
the cantilever in figure E is θ, the slope at free
A

end of the cantilever in figure F will be
M = PL/2
L
M
Figure-E
P
L
Figure-F
Answers Deflection of Beams
10.1 (d) 10.2 (*) 10.3 (d) 10.4 (c) 10.5 (c)
Explanations Deflection of Beams
10.1 (d) 10.3 (d)

P
w/m w/m L L
= E F
M=PL/2
PL2
For concentrated load θF =
Δ′ Δ 2E I
Y
w/m M ×L PL2
+ For moment at end θE = =
EI 2E I
∴ θE = θF
S
10.4 (c)
Δ
For simple supported beam
Δ′ = Δ + Δ P(2L)3 8PL3 PL3
δ= = =
A
48E I 48E I 6E I
Δ′ 1 5wL4 for cantilever:
Δ= = ×
2 2 384E I PL3
δ2 =
3E I
E
2 w/m
∴ δ 2 = 2δ
10.5 (c)
Now, Deflection in cantilever
Δ′′
E
WL3 WL3 4WL3
δ= = =
3E I 1 3
3E × bd 3 Ebd
12
5wL4
D
W 3
Δ′′ = 2Δ = 384E I 4××L 3
2 ⎛ 1 ⎞ 4WL
Now δ ' = = ⎜ ⎟
E × b × (2d)3 ⎝ 16⎠ Ebd3
δ
A
10.2 (*) δ' =

16
WL3 5WL3
δ1 = ; δ2 =
48E I 384E I
M
δ1
∴ = 1.6
δ2
Nearest answer is (b)
11 Combined Stresses
11.1 For the configuration of loading shown in the given Wt. of Shaft; Gear
Y
figure, the stress in fibre AB is given by w per Unit Length (Torque
Acting : T)
5
P P
L
e
10
S
A B
P
(a) (tensile)
A Wt. of
A
Gear : W
⎛ P P .e.5 ⎞
(b) ⎜ A − I ⎟ compressive) (a) T
⎝ xx ⎠
(b) Wl+T
⎛ P P .e.5 ⎞
E 1
(c) ⎜ A + I ⎟ compressive) ⎡ 2 ⎛ wL ⎞
2⎤2
⎝ xx ⎠ (c) ⎢(Wl ) + ⎜ ⎟ ⎥
⎢⎣ ⎝ 2⎠ ⎥
⎦
(d) P/A (compressive)
1
[ESE : 1995] ⎡⎧ 2 ⎤2
⎢ ⎪ wL2 ⎪⎫
⎬ +T ⎥
2
(d) ⎨W l +
E
11.2 The equivalent bending moment under combined ⎢ ⎪⎩ 2 ⎪⎭ ⎥
action of bending moment M and torque T is ⎣ ⎦
[ESE : 1999]
1
(a) M2 +T 2 (b) M2 +T 2
D
2 11.5 A column of square section 40 mm × 40 mm, fixed
( )
to the ground carries an eccentric load P of 1600 N
1
(c) M + M 2 + T 2 (d) M + M2 + T 2 as shown in the figure.
2
e P
A
[ESE : 1996]
11.3 A circular shaft is subjected to the combined

action of bending, twisting and direct axial loading.
The maximum bending stress σ, maximum
M
shearing stress 3σ and a uniform axial stress σ

(compressive) are produced. The maximum
compressive normal stress produced in the shaft A D
will be e
(a) 3 σ (b) 2 σ 40 mm
(c) σ (d) Zero B C

[ESE : 1998] 40 mm
If the stress developed along the edge CD is
11.4 For obtaining the maximum shear stress induced
–1.2 N/mm2, the stress along the edge AB will be
in the shaft shown in the given figure, the torque
(a) –1.2 N/mm2 (b) +1 N/mm2
should be equal to
(c) +0.8 N/mm2 (d) –0.8 N/mm2
[ESE : 1999]

Answers Combined Stresses
11.1 (b) 11.2 (d) 11.3 (a) 11.4 (d) 11.5 (d)
Explanations Combined Stresses
11.1 (b) 11.4 (d)

Total bending moment
For AB section
L wL2
P M = W l + wL = Wl +
Direct stress (σ1) = (Compressive)
Y
A
2 2
P .e.5 ∴ Equivalent torque = M 2 + T 2
Bending stress (σ2 ) = (tensile)
I xx 1
⎡⎛ 2 ⎤2
wL2 ⎞
S
total stress in fibre AB = (σ1 − σ 2 ) = ⎢ ⎜W l + + T 2⎥
⎢⎝ 2 ⎟⎠ ⎥
⎛ P P .e.5 ⎞ ⎣ ⎦
=⎜ − (compressive)
⎝A I xx ⎟⎠
11.5 (d)
11.2 (d)
Bending stress (σ) =

32M
πd 3
A A
e
D
E 40 mm
16T
Shear stress (τ) =
πd 3 B C
40 mm
Maximum normal stress
Direct stress,
E
2
σ ⎛ σ⎞ P
(σ1) = =
1600
= 1N / mm2 (compressive)
σmax = + ⎜ ⎟ + τ2
2 ⎝ 2⎠ A 40 × 40
Bending stress,
D
Pe 6 × 1600 × e
32M ⎡⎢ ⎛ 32M ⎞ ⎛ 16T ⎞ ⎤⎥
32Meq 2 2
(σ 2 ) = = = 0.15 e
⇒ = + ⎜ ⎟ + ⎜ ⎟ z (40)3
πd 3 2πd 3 ⎢ ⎝ 2πd 3 ⎠ ⎝ πd 3 ⎠ ⎥
⎣ ⎦ For edge CD.
A
1⎡ (– σ1 − σ 2 ) = −1.2 MPa ⇒ 1 + 0.15e = 1.2

∴ Meq = M + M2 + T 2 ⎤
2 ⎣⎢ ⎦⎥ ∴ e = 1.333 mm ; For edge AB,
11.3 (a) Total stress = −σ1 + σ2 = −1 + 0.15e

M
Normal stress = –2σ, 0 = –1+0.15×1.33 = – 0.8N/mm2

Shear stress = 3σ
2
−2σ ⎛ −2σ ⎞
⎟⎠ + ( 3 σ )
2
σ1, σ2 = ± ⎜
2 ⎝ 2
= −σ ± σ2 + 3σ 2 = −σ ± 2σ
= –3σ, + σ
Maximum compressive stress = 3 σ
UNIT
II
Y
Engineering Materials
S
A
Syllabus
Basic Crystallography, Alloys and Phase diagrams, Heat Treatment, Ferrous and Non Ferrous Metals, Non metallic
E
materials, Basics of Nano-materials, Mechanical Properties and Testing, Corrosion prevention and control.
E
Contents
D
1. Crystal Systems ................................................................................................................. 30

A
2. Alloy and Binary Phase Diagrams ...................................................................................... 32
3. Heat Treatment of Steels .................................................................................................... 34

M
4. Mechanical Testing & Mechanical Properties of Materials .................................................. 36
5. Plastic, Ceramic and Composite Materials ......................................................................... 38
6. Properties & Application of Various Ferrous & Non-ferrous Metals and Their Alloys .......... 40
0
1 Crystal Systems
1.1 In metals subjected to cold working, strain List-I List-II
Y
hardening effect is due to A. Charcoal 1. F.C.C.
(a) slip mechanism B. Graphite 2. H.C.P.
(b) twining mechanism C. Chromium 3. Amorphous
(c) dislocation mechanism D. Copper 4. B.C.C.
S
(d) fracture mechanism Codes:
[ESE : 1997] A B C D
(a) 3 2 1 4
1.2 Which of the following properties of a solid are
A
(b) 3 2 4 1
dependent on crystal imperfections?
(c) 2 3 4 1
1. Yield stress 2. Melting point
(d) 2 3 1 4
3. Semiconductivity 4. Ductility [ESE : 1998]
E
Select the correct answer using the codes given
below: Directions: The following items consists of two
(a) 1 and 3 (b) 1, 3 and 4 statements; one labelled as ‘Assertion (A)’ and the
(c) 2, 3 and 4 (d) 2 and 4 other as ‘Reason (R)’
(R)’. You are to examine these two
[ESE : 1997] statements carefully and select the answers to these
E
items using the codes given below:
1.3 A unit cell of a crystal is shown in given figure. Codes:
The miller indices of the direction (arrow) shown (a) both A and R are true and R is the correct
in the figure is explanation of A
D
(b) both A and R are true but R is not a correct

z
explanation of A
(c) A is true but R is false
A
(d) A is false but R is true

1
1.5 Assertion (A): Refining the grain size of
polycrystalline material renders it harder and
M
y stronger.
1
2 Reason (R): Grain boundaries provide easy
paths to dislocation motion.
1 [ESE : 1998]
2
x 1
1.6 Assertion (A): Plastic deformation in metals and
(a) [0 1 2] (b) [0 2 1] alloys is a permanent deformation under load. This
(c) [1 2 0] (d) [2 0 1] property is useful in obtaining products by cold
[ESE : 1998] rolling.
Reason (R): Plastic or permanent deformation in
1.4 Match List-I (Material) with List-II (Structure) and
metal or alloy is caused by movement of
select the correct answer using the codes given
dislocations.
below the lists:
[ESE : 1998]
Engineering Materials 31
1.7 Match List-I (Crystal structure) with List-II (Atomic (a) F = C + P (b) F = C + P – 2
packing factor) and select the correct answer (c) F = C – P – 2 (d) F = C – P + 2
using the codes given below the lists: [ESE : 1999]
List-I List-II
1.9 The set of Miller indices of the plane shown in the
A. Simple cubic 1. 74%
given figure is
B. Body-Centred cubic 2. 74%
C. Face-Centred cubic 3. 52% z
D. Hexagonal close packed 4. 68%
Codes:
Y
A B C D
(a) 3 4 2 1
(b) 4 3 2 1
(c) 3 4 1 2
S
(d) 4 3 1 2
y
[ESE : 1999] x
1.8 Gibb’s phase rule is given by (a) (1 0 0) (b) (100)
A
(F = number of degree of freedom
(c) (1 0 1) (d) (1 1 0)
C = number of components
[ESE : 1999]
P = number of phases)

E
Answers Crystal Systems
1.1 (c) 1.2 (b) 1.3 (c) 1.4 (b) 1.5 (c) 1.6 (a) 1.7 (a, c) 1.8 (d) 1.9 (b)
Explanations Crystal Systems

E
1.1 (c) 1.7 (a & c)

Dislocation mechanism is responsible for strain Both (a) & (c) are correct.
D
hardening. Crystal structure : APF
1.2 (b) Simple cubic : 0.52

BCC : 0.68
Melting point is not affected by crystal
A
imperfection semiconductivity is affected by FCC : 0.74

point defect. HCP : 0.74
1.4 (b) 1.8 (d)

M
BCC : Li, Na, K, Rb, Cs, Fr, Cr, Fe (α iron and P + F = C + 2 Gibb’s phase rule
δ iron), Mo, Nob, Ta, W, V, Zr, Ti
FCC : Ac, Al, Ca, Ce, Cu, Au, Ir, Pb, Ni, Pd, 1.9 (b)
Pt, Fe (γ iron), Rn, Rh, Ag, Sr, Th, Yb Intercept on y and z axis is ∞. So taking reciprocal
HCP : Be, Cd, Co, Mg, Os, Re, Ti, Zn, Zr and it will be 0, 0 on both x and y-axis. Intercept on
He x axis is on the negative side of x-axis (100) .
Amporphous : Glass, Charcoal

1.5 (c)
Refining of grain size means having small grain
which don’t permit movement of dislocation easily
so strength increases
2 Alloy and Binary
Phase Diagrams
2.1 Consider the following statements: (a) Ferrite and pearlite
Y
Addition of silicon to cast iron (b) Cementite and pearlite
1. Promotes graphite module formation (c) Ferrite and bainite
2. Promotes graphite flake formation (d) Cementite and martensite
3. Increases the fluidity of the molten metal [ESE : 1995]
S
4. Improves the ductility of cast iron
2.5 Addition of magnesium to cast iron increases its
Which of these statements are correct?
(a) hardness
(a) 1 and 4 (b) 2 and 3 (b) ductility and strength in tension
A
(c) 1 and 3 (d) 3 and 4 (c) Corrosion resistance
[ESE : 1995] (d) creep strength
2.2 Eutectoid reaction occurs at [ESE : 1995]
(a) 600°C (b) 723°C
E 2.6 A given steel test specimen is studied under
(c) 114°C (d) 1493° metallurgical microscope. Magnification used is
[ESE : 1995] 100 X. In that different phases are observed. One
of them is Fe3C.
2.3 Match List-I (Name of material) with List-II
The observed phase Fe3C is also known as
(% Carbon range) and select the correct answer
E
(a) ferrite (b) cementite
using the codes give below the lists:
(c) austenite (d) martensite
List-I
[ESE : 1997]
A. Hypo-eutectoid steel
D
B . Hyper-eutectoid steel 2.7 Assertion (A): Carbon would form an interstitial

C. Hypo-eutectic cast iron solid solution with iron.
D. Hyper-eutectic cast iron Reason (R): The atomic radius of iron is smaller
A
List-II than that of carbon.

1. 4.3 – 6.67 (a) both A and R are true and R is the correct
2. 2.0 – 4.3 explanation of A
3. 0.8 – 2.0 (b) both A and R are true but R is not a correct
M
4. 0.008 – 0.8 explanation of A

Codes: (c) A is true but R is false
A B C D (d) A is false but R is true
(a) 4 3 2 1 [ESE : 1998]
(b) 1 3 4 2 2.8 Heating the hypoeutectoid steels to 30°C above
(c) 4 1 2 3 the upper critical temperature line, soaking at the
(d) 1 2 3 4 temperature and then cooling slowly to room
[ESE : 1995] temperature to form a pearlite and ferrite structure,
is known as
2.4 Which one of the following sets of constituents is
(a) Hardening (b) Normalising
expected in equilibrium cooling of a
(c) Tempering (d) Annealing
hypereutectoid steel from austenitic state?
[ESE : 1999]
2.9 In a eutectic system, two elements are completely Reason (R) : The atomic radius of carbon atom
(a) Insoluble in solid and liquid state is much smaller than that of iron.
(b) Soluble liquid state (a) both A and R are true and R is the correct
(c) Soluble in solid state explanation of A
(d) Insoluble in liquid state (b) both A and R are true but R is not a correct
[ESE : 1999] explanation of A
2.10 Assertion (A) : Carbon forms interstitial solid
solution when added to iron.
[ESE : 1999]
Y

Answers Alloy and Binary Phase Diagrams
2.1 (b) 2.2 (b) 2.3 (a) 2.4 (b) 2.5 (b) 2.6 (b) 2.7 (c) 2.8 (d) 2.9 (b)
S
2.10 (a)
Explanations Alloy and Binary Phase Diagrams
2.1 (b)
Silicon is strong graphitizer and promotes
graphitization (i.e. decomposition of cementite
A 2.6 (b)
Cementite has Fe3C composition, inter metallic
compound.
E
to iron and graphite Graphitizer improves the
fluidity of iron). 2.7 (c)
Carbon in present as interstitial impurity in iron
2.2 (b) matrix. The size of iron atom is larger than that of
Eutectoid reaction is at 0.76% of carbon at 727°C carbon.
E
in iron carbon diagram in which austenite

2.8 (d)
transforms to pearlite. (% of carbon)
Slow cooling signifies cooling in furnace so it refer
D
2.3 (a) annealing process.

Hypoeutectoid steel 0.008 – 0.76%C
2.9 (b)
Hypereutectoid steel 0.76 – 2.1%C
Eutectic system implies two solid completely
A
Hypoeutectic steel 2.1 – 4.3%C

soluble in liquid system and insoluble in solid
Hypereutectic steel 4.3 – 6.64%C state
Liquid A ←⎯ ⎯⎯ → Solid B + solid C
⎯
2.4 (b)

M
Hypereutectoid steel when cooled in equilibrium

will result in pro-eutectoid cementite and pearlite
whereas hypoeutectoid steel when cooled in
equilibrium will result in pro-eutectoid ferrite and
pearlite.
3 Heat Treatment of Steels
3.1 Match List-I (Heat treatment) with List-II (Effect 3.3 Machines tool guideways are usually hardened by
Y
on the properties) and select the correct answer (a) vacuum hardening
using the codes given below the lists: (b) martempering
List-I (c) induction hardening
A. Annealing (d) flame hardening [ESE : 1996]
S
B. Nitriding 3.4 Guideways of lathe beds are hardened by
C. Martempering (a) carburizing (b) cyaniding
D. Normalising (c) nitriding (d) flame hardening
List-II
A
[ESE : 1997]
1. Refined grain structure
3.5 Two cooling curves A and B for eutectoid iron-
2. Improves the hardness of the whole mass
carbon alloy are superimposed on a continuous
3. Increases surface hardness
cooling transformation diagram as shown in the
4. Improves ductility
E
Codes: given figure. Fine pearlite microstructure is
A B C D represented by the points labelled
(a) 4 3 2 1
(b) 1 3 4 2
800 Eutectoid Temperature
E
(c) 4 2 1 3
Temperature (°C)
(d) 2 1 3 4 [ESE : 1995] 700 I

II
3.2 Consider the following statements
600 III
When a metal or alloy is cold worked IV
D
1. It is worked below room temperature 500 A B

2. It is worked below recrystallization
temperature 400
0 1 10 100 103 104
Time (sec.)
A
3. Its hardness and strength increases

4. Its hardness increases but strength does not
(a) I and III (b) II
increase
(c) IV (d) [ESE : 1998]
I[ESE
M
(a) 1 and 3 (b) 1 and 3

(c) 2 and 3 (d) 2 and 4
[ESE : 1996]
Answers Heat Treatment of Steels
3.1 (a) 3.2 (c) 3.3 (d) 3.4 (d) 3.5 (c)
Explanations Heat Treatment of Steels
3.1 (a) 3.2 (c)

Annealing is softening process which improves When metal is cold worked (below recrystalization)
ductility. Normalizing is cooling of material in air then strain hardening takes place due to which
so it refines grain structures (due to faster cooling hardness and strength both increases.
than annealing) Nitriding is employed with alloy
steel in which different alloys forms their 3.3 (d)
respective nitrides so surface hardness Flame hardening is done to increase the hardness
Y
improves. at surface and have tough core.
Martempering is two stage cooling process
3.5 (c)
avoiding the nose of TTT diagram to from
martensite. The two stage cooling minimizes Slow cooling above nose of TTT diagram will have
S
distortion and quench crack. fine pearlite. Point IV will correspond 100%
completion line.

A
E
E
D
A
M
4 Mechanical Testing & Mechanical
Properties of Materials
4.1 In low carbon steels, presence of small quantities List-I
Y
sulphur improves A. Young’s modulus
(a) weldability (b) formability B. Modulus of rigidity
(c) machinability (d) hardenability C. Bulk modulus
[ESE : 1995] D. Poisson’s ratio
S
List-II
4.2 During tensile-testing of a specimen using
1. Shear strain
Universal Testing Machine, the parameters 2. Normal strain
actually measured include
A
3. Transverse strain
(a) True stress and true strain 4. Volumetric strain
(b) Poisson’s ratio and Young’s modulus Codes:
(c) Engineering stress and engineering strain A B C D
(d) load and elongation
E (a) 1 2 3 4
[ESE : 1996] (b) 2 1 3 4
4.3 Match List-I with List-II and select the correct (c) 2 1 4 3
answer using the codes given below the lists: (d) 1 2 4 3
List-I [ESE : 1997]
E
A. Toughness Directions: The following items consists of two

B. Endurance strength statements; one labelled as ‘Assertion (A)’ and the
C. Resistance to abrasion other as ‘Reason (R)’
(R)’. You are to examine these two
D
D. Deflection in beam statements carefully and select the answers to these

List-II items using the codes given below:
1. Moment area method Codes:
2. Hardness
A
(a) both A and R are true and R is the correct

3. Energy absorbed before fracture in a tension explanation of A
test (b) both A and R are true but R is not a correct
4. Fatigue loading explanation of A
M
Codes: (c) A is true but R is false

A B C D (d) A is false but R is true
(a) 4 3 1 2 4.5 Assertion (A) : The notch sensitivity of cast iron
(b) 4 3 2 1 component is zero.
(c) 3 4 2 1 Reason (R) : Cast iron does not have yield point.
(d) 3 4 1 2 [ESE : 1997]
[ESE : 1997]
4.6 Assertion (A) : Specimens for impact testing are
4.4 Match List-I (Elastic properties of an isotropic never notched.
elastic material) with List-II (Nature of strain Reason (R) : A notch introduces tri-axial tensile
produced) and select the correct answer using stresses which cause brittle fracture.
the codes given below the lists: [ESE : 1999]

Answers Mechanicals Testing & Mechanical Properties of Materials

4.1 (c) 4.2 (d) 4.3 (c) 4.4 (c) 4.5 (b) 4.6 (d)
Explanations Mechanicals Testing & Mechanical Properties of Materials

4.1 (c) Change in pressure
Bulk modulus =
Sulphur forms MnS when manganese is added Volumetric strain
which increases machinability. Its amount is Lateral strain
controlled because formation of FeS leads to hot Poisson’s ratio =
Longitudinal strain
Y
shortness as FeS is low melting eutectic.
4.5 (b)
4.2 (d)
Notch sensitivity of gray cast iron is zero because
Load and elongation is measured in tensile test.
of presence of graphite flakes which have itself
S
4.3 (c) many notches so practically insensitive for stress
concentration.
Endurance strength is used in fatigue loading.
Deflection in beam in related to moment area
A
4.6 (d)
method.
Specimen of impact testing are notched (45°) to
4.4 (c) test the behaviour of ductile material for failure
Young’s modulus (E ) =
Normal stress
E as brittle material when tri-axial stress induced
Normal strain in it. This test is also used to check the
susceptibility of material for ductile to brittle
Shear stress
Modulus of rigidity (G) = transition.
Shear strain

E
D
A
M
5 Plastic, Ceramic and
Composite Materials
5.1 The structure of a polymer is shown in the given 5.4 Consider the following statements
Y
figure. This polymer finds special application in Fibre Reinforced plastic are:
1. Made of thermosetting resins and glass fibre
F F 2. Made of thermoplastic resins and glass fibre.
| | 3. Anisotropic
S
—C—C— 4. Isotropic
| | Which of these statements are correct?
F F
(a) 1 and 4 (b) 1 and 3
A
(c) 2 and 3 (d) 2 and 4
(a) packaging (b) adhesives
[ESE : 1996]
(c) bearings (d) fertilizer
[ESE : 1995] 5.5 Match List-I with List-II and select the correct
E answer using the codes given below the lists:
5.2 Consider the following statements: List-I
Thermosetting plastic are A. Neoprene
1. Formed by addition polymerization B. Bakelite
2. Formed by condensation polymerization
E
C. Foamed poly-urethane
3. Softened on heating and hardened on cooling D. Araldite
for any number of times
List-II
4. modulated by heating and cooling
D
1. Electric switches
2. Adhesive
(a) 1 and 3 (b) 2 and 4
3. Thermal insulator
(c) 1 and 4 (d) 2 and 3
4. Oil seal
A
[ESE : 1996]
Codes:
5.3 Match List-I and List-II and select the correct A B C D
answer using the codes given below the lists: (a) 4 1 2 3
M
List-I List-II (b) 1 4 2 3

A. Polyethylene 1. Adhesive (c) 4 1 3 2
B. Polyurethane 2. Film (d) 1 4 3 2 [ESE : 1997]
C. Cyanoacrylate 3. Wire 5.6 Which one of the following materials is used for
D . Nylon 4. Foam car tyres as a standard material?
Codes: (a) Styrene-butadiene Rubber (SBR)
A B C D (b) Butyl rubber
(a) 2 4 3 1 (c) Nitrile rubber
(b) 4 2 3 1 (d) Any one of the above depending upon the
(c) 2 4 1 3 need [ESE : 1997]
(d) 4 2 1 3
[ESE : 1996]
5.7 Consider the following statements: 5.8 Consider the following pairs of plastics and their
The strength of the fibre reinforced plastic product distinct characteristics:
1. Depends upon the strength of the fibre alone 1. Acrylics...Very good transparency to light
2. Depends upon the fibre and plastic 2. Polycarbonate...Poor impact resistance
3. Is isotropic 3. PTFE...Low coefficient of friction
4. Polypropylene...Excellent fatigue strength
4. Is anisotropic
(a) 2 and 3 (b) 1 and 3
(a) 1 and 3 (b) 1 and 4
(c) 1 and 4 (d) 2 and 4 [ESE : 1999]
(c) 2 and 3 (d) 2 and 4 [ESE : 1999]
Y

Answers Plastic, Ceramic and Composite Materials
S
5.1 (c) 5.2 (b) 5.3 (c) 5.4 (b) 5.5 (c) 5.6 (a) 5.7 (d) 5.8 (b, c)
Explanations Plastic, Ceramic and Composite Materials
A
5.1 (c) (ii) Bakelite has excellent thermal stability to
over 150°C and may be compounded with a
It is monomer of Poly-Tetra-Fluro-Ethene (PTFE).
large number of resins, fillers. It is used in
It is chemically inert in almost all environment,
motor housing, telephones, auto distributor
excellent electrical properties, low coefficient of
E and electrical fixtures.
friction. It is used as anti-corrosive seals, chemical
(iii) Foamed Polyurethane are commonly used
pipes and valves, bearings, anti adhesive
as cushions in auto mobiles and furniture
coating, high temperature electronic parts.
as well as in packaging and thermal
5.2 (b) insulation.
E
Thermosetting plastic become soft during their (iv) Araldite has excellent combination of
first heating and become very hard during mechanical properties and corrosion
cooling. They do not soften during subsequent resistance, dimensionally stable, good
D
heating and rather become harder during cooling. adhesion, relatively inexpensive and good
electrical properties.
5.5 (c)
5.8 (b, c)
(i) Neoprenes are used as wire and cable,
A
chemical tank linings, belts, hoses, seals Poly-tetra-fluoro-ethylene has very low coefficient
and gaskets. It has excellent ozone, heat of friction and it does not stick to other materials.
and weathering resistance and also good Poly propylene has the capability to be bent
repeatedly and no crack will develop in it.
M
oil resistance.

Properties & Application of Various
6 Ferrous & Non-ferrous Metals
and Their Alloys
Y
6.1 Match List-I (Alloy )with List-II (Use) and select (a) Chromium (b) Silicon
the correct answer using the codes give below (c) Manganese (d) Magnesium
the lists: [ESE : 1996]
S
List-I
6.5 Which of the following pairs regarding the effect
A. Low carbon steel
of alloying elements in steel are correctly
B. Hadfield manganese steel
matched?
A
C. Constantan
1. Molybdenum : Forms abrasion resisting
D. Babbitt alloy
particles
List-II
2. Phosphorous : Improves mechanability in free
1. Bearing
E cutting steels
2. Thermocouple
3. Cobalt : Contributes to red hardness by
3. Wire nails
hardening ferrite
4. Bulldozer blades
4. Silicon Reduces oxidation resistance
Codes:
A B C D
E
(a) 2, 3 and 4 (b) 1, 3 and 4
(a) 1 2 3 4
(c) 1, 2 and 3 (d) 1, 2 and 4
(b) 3 4 1 2
[ESE : 1996]
(c) 3 2 1 4
D
(d) 3 4 2 1 [ESE : 1995] 6.6 Assertion (A) : Austenitic stainless steel contains
18% chromium and 8% nickel. Since it retains its
6.2 18/8 stainless steel contains
austenitic structure at room temperature, it is
(a) 18% stainless, 8% chromium
called austenitic stainless steel.
A
(b) 18% chromium, 8% nickel

Reason (R) : Chromium present in the steel
(c) 18% tungsten, 8% nickel
improves its corrosion resistance by forming a
(d) 18% tungsten, 8% chromium
thin film of chromium oxide on the surface.
[ESE : 1996]
M

6.3 Tin base white metals are used where the bearings explanation of A
are subjected to (b) both A and R are true but R is not a correct
(a) large surface wear explanation of A
(b) elevated temperature (c) A is true but R is false
(c) light load and pressure (d) A is false but R is true
(d) high pressure and load, [ESE : 1997]
[ESE : 1996]
6.7 Match List-I (Alloying element in steel) with List-II
6.4 Alloy steel which is work hardenable and which is (Property conferred on steel by the element) and
used to make the blades of bulldozers, bucket select the correct answer using the codes given
wheel excavators and other earth moving below the lists:
equipment contain iron, carbon and
List-I List-II 6.9 Assertion (A) : Cast iron is generally hard, brittle
A. Nickel 1. Corrosion resistance and wear resistant.
B. Chromium 2. Magnetic permeability Reason (R) : Cast iron contains more than 20%
C. Tungsten 3. Heat resistance carbon and as such the percentage cementite in
D. Silicon 4. Hardenability it is higher.
Codes: (a) both A and R are true and R is the correct
A B C D explanation of A
(a) 4 1 3 2 (b) both A and R are true but R is not a correct
(b) 4 1 2 3 explanation of A
Y
(c) 1 4 3 2 (c) A is true but R is false
(d) 1 4 2 3 [ESE : 1998] (d) A is false but R is true [ESE : 1998]
6.8 Match List-I (Alloys) with List-II (Applications) and 6.10 Match List-I (Material) with List-II (Applications)
S
select the correct answer using the codes given and select the correct answer using the codes
below the lists: given below the Lists:
List-I List-I
A. Chromel B. Babbit alloy A. Tungsten carbide B. Silicon nitride
A
C. Nimonic alloy D. High speed steel C. Aluminium oxide D. Silicon carbide
List-II List-II
1. Journal bearing 1. Abrasive wheels
2. Milling cutter
E 2. Heating elements
3. Thermocouple wire 3. Pipes for conveying liquid metals
4. Gas turbine blades 4. Drawing dies
Codes:
Codes:
A B C D
A B C D
E
(a) 3 1 4 2
(a) 3 4 1 2
(b) 3 4 1 2
(b) 4 3 2 1
(c) 2 4 1 3
(c) 3 4 2 1
(d) 2 1 4 3 [ESE : 1998]
D
(d) 4 3 1 2 [ESE : 1999]

Answers Properties & Application of Various Ferrous and Non-ferrous Metals and Their Alloys
A
6.1 (d) 6.2 (b) 6.3 (a) 6.4 (c) 6.5 (c) 6.6 (b) 6.7 (a) 6.8 (a) 6.9 (c)
6.10 (d)
M
Explanations Properties & Application of Various Ferrous and Non-ferrous Metals and Their Alloys
6.1 (d) • Low carbon steel is used in wire nails.
• Hadfield manganese steel has high surface 6.2 (b)

hardness and tough core so used as bulldozer 18/8 signifies 18% Chromium and 8% nickel. It is
blades. also called austenitic stainless steel, non-
• Constantan is nickel based alloy used as magnetic in nature, Titanium & niobium added to
Thermocouple. stabilize the carbon.
• Babbit alloy are copper based alloy having
6.3 (a)
tin, zinc, lead or arsenic. It is used as bearing
Tin based babbits have better corrosion and wear
material.
resistance as compared to lead based babbits.
Lead is added to these babbits to reduce their 6.7 (a)

cost however lead decreases the load bearing Nickel : Increases hardenability
ability of these bearing. Chromium : Corrosion resistance
Tungsten : Heat resistance
6.4 (c)
Silicon : Improves magnetic permeability
Hadfield manganese steel has high surface
hardness and tough core so used as bulldozer 6.9 (c)
blades. Percentage of carbon is 6.67% (limited) in Fe–C
alloys
6.5 (c)
Y
Silicon are strong oxidizer. 6.10 (d)
Aluminium oxide : Abrasive wheel
Tungsten carbide : Drawing dies
S

A
E
E
D
A
M
UNIT
III
Y
Mechanisms and Machines
S
Syllabus
A
Types of Kinematics Pair, Mobility, Inversions, Kinematic Analysis, Velocity and Acceleration Analysis of Planar
Mechanisms, CAMs with uniform acceleration and retardation, cycloidal motion, oscillating followers; Vibrations –
Free and forced vibration of undamped and damped SDOF systems, Transmissibility Ratio, Vibration Isolation, Critical
E
Speed of Shafts. Gears – Geometry of tooth profiles, Law of gearing, Involute profile, Interference, Helical, Spiral and
Worm Gears, Gear Trains- Simple, compound and Epicyclic; Dynamic Analysis – Slider – crank mechanisms, turning
moment computations, balancing of Revolving & Reciprocating masses, Gyroscopes –Effect of Gyroscopic couple
on automobiles, ships and aircrafts, Governors, Flywheel.
E
Contents
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1. Displacement, Velocity and Acceleration ........................................................................... 44

A
2. Planar Mechanism .............................................................................................................. 47

3. Cams ................................................................................................................................. 51
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4. Dynamic Analysis of Slider-crank ....................................................................................... 52

5. Gear and Gear Train ........................................................................................................... 53
6. Flywheel ............................................................................................................................. 58
7. Vibration ............................................................................................................................. 60
8. Governors .......................................................................................................................... 67
9. Balancing and Gyroscope .................................................................................................. 70
10. Miscellaneous .................................................................................................................... 73

1 Displacement, Velocity
and Acceleration
1.1 The instantaneous centre of rotation of a rigid thin

D
Y
disc rolling on a plane rigid surface is located at
(a) the centre of the disc 4
(b) an infinite distance on the plane surface C
(c) the point of contact
S
3
(d) the point on the circumference situated
vertically opposite to the contact point
[ESE : 1995] B
2
A
1.2 The directions of Coriolis component of
acceleration, 2ωV, of the slider A with respect to A 1
the coincident point B is shown in figure 1, 2, 3

and 4. Directions shown by figures
E
(a) the centre of swivel trunnion
V ω V ω (b) the intersection of line AB and a perpendicular
2ωV 2ωV 2ωV 2 ωV to BD to
B B B B
A A A A (c) infinity along AC
(d) infinity perpendicular to BD
E
ω V ω V [ESE : 1996]
1.5 The instantaneous centre of motion of rigid thin

D
disc wheel rolling on plane rigid surface shown in

0 0 0 0
Fig. 1 Fig. 2 Fig. 3 Fig. 4
the figure, is located at the point
∞+ D
(a) 2 and 4 are wrong
A
(b) 1 and 2 are wrong B

(c) 1 and 3 are wrong
(d) 2 and 3 are wrong C
[ESE : 1995]
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1.3 The centre of gravity of the coupler link in a 4-bar A
mechanism would experience

(a) no acceleration (a) A (b) B
(b) only linear acceleration (c) C (d) D
(c) only angular acceleration [ESE : 1996]
(d) both linear and angular accelerations 1.6 In the figure shown, crank AB is 15 cm long and
[ESE : 1996] is rotating at 10 rad/s C is vertically above A. CA
1.4 In the Mechanism ABCD shown in the given figure, equals 25 cm. C is a swivel trunnion through which
the fixed link is denoted as (1), Crank AB as (2) BD (40 cm.) Slides. If ABCD becomes a vertical
rocker BD (3), Swivel trunnion at C as (4) The line during its motion, the angular velocity of the
instantaneous centre I41 is at swivel trunnion at that instant will be
Mechanisms and Machines 45
(a) 2V ω (b) V ω
D (c) Vω/2 (d) 2Vω [ESE : 1998]
1.10 The total number of instantaneous centres for a

C mechanism consisting of ‘n’ links is
(a) n/2 (b) n
n −1 n (n − 1)
(c) (d)
25 cm 2 2
[ESE : 1998]
Y
B
15 cm 1.11 In SHM, with respect to the displacement vector,
10 rad/s
A the positions of velocity vector and acceleration
vector will be respectively
S
(a) (150/10) rad/s (b) (100/25) rad/s (a) 180° and 90° (b) 90° and 180°
(c) (100/15) rad/s (d) (100/10) rad/s (c) 0° and 90° (d) 90° and 0°
[ESE : 1997] [ESE : 1998]
A
1.7 In order to draw the acceleration diagram, it is 1.12 The relative acceleration of two points which are
necessary to determine the Coriolis component at variable distance apart on a moving link can
of acceleration in the case of be determined by using the
(a) crank and slotted lever quick return
E (a) three centres in line theorem
mechanism (b) instantaneous centre of rotation
(b) slider-crank mechanism (c) Coriolis component of acceleration method
(c) four bar mechanism (d) Klein’s construction
(d) pantograph [ESE : 1999]
E
[ESE : 1997] 1.13 Consider a four-bar mechanism shown in the given
1.8 Two links OA and OB are connected by a pin figure. The driving link DA is rotating uniformly at
joint at ‘O’. The link OA turns with angular velocity a speed of 100 r.p.m clockwise.
D
ω1 radians per second in the clockwise direction B
and the link OB turns with angular velocity ω2 cm

36
radians per second in the anticlockwise direction.
A m
c
A
If the radius of the pin at ‘O’ is ‘r’, then the rubbing 36

velocity at the pin joint ‘O’ will be 30 cm
(a) ω1.ω 2 .r (b) (ω1 − ω 2 )r 60°

C
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D 60 cm
(c) (ω1 + ω 2 )r (d) (ω1 − ω 2 )2r
[ESE : 1998] The velocity of A will be
(a) 300 cm/s (b) 314 cm/s
1.9 When a slider moves with a velocity ‘V’ on a link
(c) 325 cm/s (d) 400 cm/s
rotating at an angular speed of ω the Coriolis
[ESE : 1999]
component of acceleration is given by

Answers Displacement, Velocity and Acceleration
1.1 (c) 1.2 (a) 1.3 (d) 1.4 (a) 1.5 (a) 1.6 (a) 1.7 (a) 1.8 (c) 1.9 (d)
1.10 (d) 1.11 (b) 1.12 (c) 1.13 (b)

Explanations Displacement, Velocity and Acceleration

1.1 (c) uur uuur
Vrubbing = rb (ω1 − ω2 ) = (ω1 + ω2) rb
If the two links form a higher kinematic pair with
pure rolling. Than their instantaneous centre lies 1.9 (d)
ur ur
at the point of contact it self. Coriolis components = 2ω × V
1.2 (a)
1.10 (d)
acoriolis = 2ωv
n(n − 1)
Along a line rotated 90° from the sliding velocity Total number of I.C. =
Y
2
vector in a direction same as that of the angular
velocity of the slotted lever. 1.11 (b)
1.3 (d) Let x = A sinωt
S
V = Aω cos ωt = Aω sin(ωt + 90°)
The centre of gravity of the link in a 4-bar F = –Aω2 sinωt = Aω2 sin(ωt + 180°)
mechanism would experience both linear and
angular acceleration. 1.12 (c)
1.4 (a)
D
A The correct option is (c) i.e., Coriolis component

of acceleration method.
• Instantaneous centre of rotation method is
E used for the analysis of velocity only and not
for acceleration.
I34 I14
• Klein’s construction is used for only slides and
crank mechanism.
B I23
• Therefore the relative acceleration of two point
E
(like in withworth quick return mechanism)
which are at variable distance apart on a
A I12 moving link can be determined by Coriolis
D
component of acceleration method.

1.5 (a)
1.13 (b)
If the two links form a higher kinematic pair with B
A
pure rolling. Than their instantaneous centre lies 36 cm

at the point of contact itself. A
1.7 (a)
36 cm
In crank and slotted lever quick return mechanism 30 cm
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there exists coincident points in two kinematic

links and hence, the sliding pair revolve which
D
give Coriolis components of acceleration 60 cm C
1.8 (c) 2π × 100

V = rω = 30 × = 314 cm/s
60

ω1
ω2
2 Planar Mechanism
2.1 A round bar A passes through the cylindrical hole 2.4 Assertion (A): The Ackermann steering gear is
Y
in B as shown in the given figure. Which one of commonly used in all automobiles.
the following statements is correct in this regard? Reason (R): It has the correct inner turning
angle θ for all positions.
[ESE : 1996]
S
2.5 Which of the following statements regarding laws
governing the friction between dry surface are
B correct?
A
A 1. The friction force is dependent on the velocity
of sliding.
2. The friction force is directly proportional to
(a) The two links shown form a kinematic pair
(b)
E
The pair is completely constrained
the normal force.
3. The friction force is dependent on the materials
(c) The pair has incomplete constraint
of the contact surfaces.
(d) The pair is successfully constrained
4. The Friction force is independent of the area
[ESE : 1995]
of contact surfaces.
E
Directions: The following items consists of two (a) 2, 3 and 4 (b) 1 and 3
statements; one labelled as ‘Assertion’ and the other (c) 2 and 4 (d) 1, 2,3 and 4
as ‘Reason’
‘Reason’. You are to examine these two statements [ESE : 1996]
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carefully and select the answers to these items using

2.6 Asser tion (A)
Assertion (A): The given line diagram of Watt’s
the codes given below:
indicator mechanism is a type of crank and lever
Codes:
mechanism.
A
E
explanation of A
B D
explanation of A C
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A F
2.2 Assertion (A): The elements of higher pairs must G

be force closed.
Reason (R): This is required in order to provide Reason (R)
(R): BCD acts as a lever.
completely constrained motion. (a) both A and R are true and R is the correct
2.3 Assertion (A): Hydraulic fluid is one form of link. (b) both A and R are true but R is not a correct
Reason (R): A link need not necessarily be a explanation of A
rigid body but it must be a resistant body. (c) A is true but R is false
[ESE : 1996] (d) A is false but R is true
[ESE : 1997]
2.7 Match List-I with List-II and select the correct

answer using the codes given below the lists:
List-I
A. Quadric cycle chain
B. Single slider crank chain
C. Double slider crank chain 3.
D. Crossed slider crank chain
List-II
1. Rapson’s slide
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2. Oscillating cylinder engine mechanism
3. Ackermann steering mechanism
4. Oldham coupling 4.
Codes:
S
A B C D Select the correct answer using the codes given
(a) 1 2 4 3 below :
(b) 4 3 1 2 (a) 1, 3 and 4 (b) 2 and 4
A
(c) 3 2 4 1 (c) 1, 2 and 3 (d) 1, 2, 3 and 4
(d) 3 4 2 1 [ESE : 1998]
[ESE : 1997]
2.10 Which of the following pairs are correctly
E
2.8 Which of the following pair(s) is /are correctly matched? Select the correct answer using the
matched? codes given below the pairs.
I. Four bar chain : Oscillating- oscillating Mechanism
converter 1. Whitworth quick return motion
II. Inertia governor : Rate of change of engine 2. Oldham’s coupling
E
speed 3. Scotch yoke
III. Hammer blow : Reciprocating Chain from which derived
unbalanced mass 1. Single slider crank chain
Select the correct answer using the codes given 2. Four bar chain
D
below : 3. Double Slider crank chain

(a) I alone (b) I, II and III Code:
(c) II and III (d) I and III (a) 1 and 2 (b) 1, 2 and 3
A
[ESE : 1998] (c) 1 and 3 (d) 2 and 3

[ESE : 1998]
2.9 Which of the following are examples of a kinematic
chain? 2.11 Which one of the following figures representing
Hooke’s jointed inclined shaft system will result
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in a velocity ratio of unity?
(a) α α
1.
(b) α β
(c) α α/2
2. (d) α β/2
[ESE : 1998]
2.12 Match List-I with List-II and select the correct A

answer using the codes given below the lists: F
P
List-I
A. 4 links, 4 turning pairs a
B. 3 links, 3 turning pairs

C. 5 links, 5 turning pairs F CG F
D. footstep bearing
List-II B
1. Complete constraint
This will result in
2. Successful constraint
Y
(a) an inertia force F(→) through the CG and no
3. Rigid frame
inertia torque
4. Incomplete constraint
(b) an inertia torque F.a ( ) and no inertia
Codes:
force
S
A B C D
(c) both inertia force F(→) through the CG and
(a) 3 1 4 2
inertia torque F.a ( )
(b) 1 3 2 4
(d) both inertia force F(←) through the CG and
(c) 3 1 2 4
A
inertia torque F.a ( ) [ESE : 1999]
(d) 1 3 4 2 [ESE : 1999]
2.14 In a single slider four-bar linkage when the slider
2.13 A link AB is subjected to a force F ( ) at a point
is fixed, it form a mechanism of
P perpendicular to the link at a distance a from
the CG as shown in the figure
E (a) hand pump
(b) reciprocating engine
(c) quick return
(d) oscillating cylinder [ESE : 1999]

E
Answers Planar Mechanism
2.1 (c) 2.2 (a) 2.3 (a) 2.4 (c) 2.5 (a) 2.6 (d) 2.7 (c) 2.8 (b) 2.9 (d)
D
2.10 (c) 2.11 (a) 2.12 (d) 2.13 (c) 2.14 (a)
Explanations Planar Mechanism
A
2.1 (c) 2.2 (a)

A round bar in a cylindrical hole can revolve as Elements of higher pair like follower in cam is
well as reciprocate. Therefore, the pair is under the action of gravity or spring force.
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incompletely constrained i.e. relative motion is

2.3 (a)
possible in more than one direction.
A rectangular bar in a rectangular hole can only Link need not necessarily be a rigid body but it
reciprocate. Therefore, the pair is completely must be a resistant body so that it is capable of
constrained i.e. relative motion is possible in only transmitting motion from one member to another
one direction. without appreciable deformation in it. For eg: in
Foot step bearing in a shaft is an example of hydraulic lifts it transmits motion.
successfully constrained motion. i.e. the motion
2.4 (c)
is made constrained with some external forces.
Ackermann steering gear fulfils fundamental
equation for gearing at middle and two extreme
positions not in all positions.
2.5 (a) 2.9 (d)

Laws of friction: For kinematic chain
The force of solid friction 3l = 2p – 4
1. is directly proportional to normal force between where, l = number of link; p = number of pair
the two surfaces here p = 4 ∴l =4
2. opposes the motion between the surfaces
2.10 (c)
3. depends upon the material of the two surfaces
4. is independent of the area of contact Oldham’s coupling → Double slider crank chain
5. is independent of the velocity of sliding
Y
2.11 (a)
The last of these laws (i.e. point 5) is not true in
For double Hooke’s joint θA and θB are equal for
the strict sense as it has been found that the
friction force decreases slightly with the increase ωB
all the time and hence, speed ratio, is always
S
in velocity. ωA
Only option (2) and (3) is correct. unity.
2.6 (d) 2.12 (d)
A
A Watt’s indicator diagram, also known as Watt’s If l = (2p – 4) → Complete constraint
straight line mechanism or double lever l > (2p – 4) → Rigid frame
mechanism, consists four link (as shown in l < (2p – 4) → Incomplete constraints
E
figure). Link BCD and EF acts as lever. The
2.14 (a)
displacement of link BFD is directly proportional
If is the fourth inversion of slider crank chain when
to the pressure of gas or steam which acts on
slider is fixed
the plunger.
E
2.7 (c)
4-Bar Mechanism: 2
(1) Quadric cycle chain → Ackermann steering 1

D
(2) Single slider crank chain → oscillating 3

4
cylinder engine mechanism
(3) Double slider crank chain → Oldham
coupling
A
(4) Crossed slider crank chain → Rapson’s

slide

2.8 (b)
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Four bar chain: Oscillating-oscillating converter.

Inertia governor: Rate of change of engine
speed.
Hammer blow: Reciprocating unbalanced mass.
3 Cams
3.1 In a cam drive with uniform velocity follower, the (a) decrease the side thrust between the follower
and guide
Y
slope of the displacement must be as shown in
Fig. I. But in actual practice it is as shown in Fig. II (b) decrease the wear between follower and cam
(i.e. rounded at the corners). surface
(c) take care of space limitation
S
S
S (d) reduce the cost [ESE : 1998]
3.3 For a given lift of the follower in a given angular

motion of the cam, the acceleration/ retardation
A
of the follower will be the least when the profile of
the cam during the rise portion is
O O
(a) such that the follower motion is simple
Fig. I Fig. II
harmonic
This is because of
(a) the difficulty in manufacturing cam profile
E (b) such that the follower motion has a constant
velocity from start to end
(b) loose contact of follower with cam surface
(c) a straight line, it being a tangent cam
(c) The acceleration in the beginning and
(d) such that the follower velocity increases
retardation at the end of stroke would require
linearly for half the rise portion and then
to be infinitely high
decreases linearly for remaining half of the
E
(d) uniform velocity motion is a partial parabolic
rise portion [ESE : 1999]
motion [ESE : 1996]
3.2 In a cam drive, it is essential to offset the axis of
a follower to
D
Answers Cams
3.1 (c) 3.2 (b) 3.3 (b)

A
Explanations Cams
3.1 (c) 3.2 (b)

M
Uniform Velocity Motion If the follower movement is displacement from

the cam centre then the follower is called as an
Displacement offset follower, offsetting results in reduced forces
θ
and stresses. The offsetting eccentricity should
Out Dwell Return
stroke be in the direction to improve force components
Velocity
tending to jam the translating follower in its
θ bearing guide and decrease the wear between
follower and cam surface.
Acceleration ∞
∞
θ
∞ ∞
Jerk ∞
∞
θ
∞ ∞
4 Dynamic Analysis of
Slider-crank
4.1 With reference to the engine mechanism shown 4.2 What is the correct sequence of the following
Y
in the given figure, match List-I with List-II and steps in engine analysis?
select the correct answer using the codes given 1. Vibration analysis.
below the lists: 2. Inertia force analysis.
FC 3. Balancing analysis.
S
FW 4. Velocity and Acceleration analysis.
FD
G
below :
A
(a) 2, 4, 1, 3 (b) 2, 4, 3, 1
P W
(c) 4, 2, 1, 3 (d) 4, 2, 3, 1
FR O
[ESE : 1997]
FQ
List-I List-II
E 4.3 Which one of the following pairs is correctly
matched?
A. FQ 1. Inertia force of reciprocating mass
(a) Governor : Interference
B. FR 2. Inertia force of connecting rod
(b) Gears : Hunting
C. FW 3. Crank effort
(c) Klein’s construction : acceleration of piston
D. FC 4. Piston side thrust
E
(d) Cam : Pinion [ESE : 1999]
Codes:
A B C D
(a) 1 2 4 3
D
(b) 1 2 3 4
(c) 4 1 2 3
(d) 4 1 3 2 [ESE : 1996]
A
Answers Dynamic Analysis of Slider-crank
4.1 (c) 4.2 (d) 4.3 (c)

M
Explanations Dynamic Analysis of Slider-crank
4.1 (c) 4.3 (c)

FQ : Piston side thrust
Governor Hunting
FR : Inertia force of reciprocating mass
Gear Interference
FW : Inertia force of connecting rod
Klein's cons- acceleration of
Fc : Crank effort
truction piston
4.2 (d) Cam Follower
The correct option is (d) i.e., the correct sequence
is velocity and acceleration analysis → Inertial
force analysis → Balancing analysis → Vibration
analysis.
5 Gear and Gear Train
5.1 Klein’s construction for determining the (c) To connect non-parallel and non-intersecting
Y
acceleration of piston P is shown in the given shafts ........... Spiral gearing
figure. When N coincides with O (d) Diminished noise and smooth operation
............ Helical gears [ESE : 1995]
K
S
C 5.4 Which one of the following is true for involute
Q
M gears?
L (a) Interference is inherently absent
P N O
B (b) Variation in centre distance of shaft increases
A
radial force
(c) A convex flank is always in contact with
Crank circle
concave flank
E
(a) acceleration of piston is zero and its velocity (d) Pressure angle is constant through the teeth
is zero engagement
(b) acceleration is maximum and velocity is [ESE : 1995]
maximum 5.5 The gear train usually employed in clocks is a
(c) acceleration is maximum and velocity is zero (a) reverted gear train
E
(d) acceleration is zero and velocity is maximum (b) simple gear train
[ESE : 1995] (c) sun and planet gear
5.2 A torsional system with discs of moment of inertia (d) differential gear [ESE : 1995]
D
I1 and I2, shown in the given figure, is gear driven 5.6 Match List-I with List-II and select the correct
such that the ratio of the speed of shaft B to shaft answer using the codes given below the lists:
A is ‘n ’. Neglecting the inertia of gears, the List-I
A
equivalent inertia of disc of B at the speed of

A. Interference
shaft A is equal to
B. Dynamic load on tooth
C. Static load
I1
M
A D. Contact ratio
List-II
1. Arc of approach, arc of recess, circular pitch
B I2 2. Lewis equation
3. Minimum number of teeth on pinion
4. Inaccuracies in tooth profile
(a) nI2 (b) n2I2 Codes:
(c) I2/n2 (d) I2/n [ESE : 1995] A B C D
5.3 Which one of the following pairs is not correctly (a) 3 4 1 2
matched? (b) 1 2 3 4
(a) Positive drive ........... Belt drive (c) 4 3 2 1
(b) High velocity ratio ............ Worm gearing (d) 3 4 2 1 [ESE : 1995]
5.7 A fixed gear having 200 teeth is in mesh with 2. For involute gears the pressure angle changes
another gear having 50 teeth. The two gears are with change in centre distance between gear.
connected by an arm. The number of turns made 3. The velocity ratio of compound gear train
by the smaller gear for one revolution of arm about depends upon the number of teeth of the
the centre of the bigger gear is input and output gears only.
2 4. Epicyclic gear trains involve rotation of at least
(a) (b) 3
4 one gear axis about some other gear axis.
(c) 4 (d) 5 (a) 1, 2 and 3 (b) 1 and 3
[ESE : 1996]
(c) 1, 2 and 4 (d) 2, 3 and 4
Y
5.8 An involute pinion and gear are in mesh. If both [ESE : 1996]
have the same size of addendum, then there will
5.11 Match List-I (Positioning of two shafts) with List-II
be an interference between the
(Possible connection) and select the correct
(a) tip of the gear tooth and flank of pinion
S
(b) tip of the pinion and flank of gear
List-I
(c) flanks of both gear and pinion
(d) tips of both gear and opinion A. Parallel shafts with slight offset
A
[ESE : 1996] B. Parallel shafts at a reasonable distance
C. Perpendicular shafts
5.9 A compound train consisting of spur, bevel and
D. Intersecting shafts
spiral gears is shown in the given figure along
List-II
with the teeth numbers marked against the
E
wheels. Overall speed ratio of the train is 1. Hooks joint
2. Worm and wheel
20 3. Oldham coupling
Driver 4. Belts and pulley
E
Codes:
A B C D
35
(a) 4 3 2 1
D
(b) 4 3 1 2
70 (c) 3 4 1 2
40 (d) 3 4 2 1
A
[ESE : 1997]
Driven 25 5.12 A reverted gear train is one in which the output

shaft and input shaft
50
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(a) rotate in apposite directions

(a) 8 (b) 2 (b) are coaxial
(c) are at right angles to each other
1
(c) (d) None of these (d) are at an angle to each other
2
[ESE : 1997]
[ESE : 1996]
5.13 In the case of an involute toothed gear, involute
5.10 Which of the following statements are correct?
starts from
1. For constant velocity ratio transmission
(a) addendum circle
between two gears, the common normal at
(b) dedendum circle
the point of contact must always pass through
(c) pitch circle
a fixed point on the line joining the centres of
(d) base circle [ESE : 1997]
rotation of the gears.
5.14 In the epicyclic gear train shown in the given These characteristics which are applicable to stub
figure, ‘A’ is fixed. A has 100 teeth and B has 20° involute system would include
20 teeth. If the arm C makes three revolutions, (a) 1 only (b) 2, 3 only 4
the number of revolutions made by B will be (c) 1, 2 and 3 (d) 1, 2, 3 and 4
[ESE : 1998]
B
5.18 When two shafts are neither parallel nor
intersecting, power can be transmitted by using
C (a) a pair of spur gears
(b) a pair of helical gears
Y
A
(c) an Oldham’s coupling
(d) a pair of spiral gears [ESE : 1998]
5.19 Consider the following statements:
S
(a) 12 (b) 15 A pinion of 14½ ° pressure angle and 48 involute
(c) 18 (d) 24 [ESE : 1997] teeth has a pitch circle diameter of 28.8 cm. It has
1. module of 6 mm
5.15 Two geared shaft A and B having moments of
A
2. circular pitch of 18 mm
inertia Ia and Ib and angular acceleration αa and
αb respectively are meshed together. B rotates at 3. addendum of 6 mm
G times the speed of A. If the gearing efficiency 4. diametral pitch of 11/113
of the two shafts in η then in order to accelerate Which of these statements are correct?
E (a) 2 and 3 (b) 1 and 3
B, the torque which must be applied to A will be
(a) Iaαa + G2Ibαb/η (b) G2Ibαaη (c) 1 and 4 (d) 2 and 4 [ESE : 1999]
(c) G Iaαaη
2 (d) G2lbαbη [ESE : 1998] 5.20 Consider the following statements regarding the
5.16 The working surface above the pitch surface of choice of conjugate teeth for the profiles of mating
E
the gear tooth is termed as gears:
(a) addendum (b) dedendum 1. They will transmit the desired motion.
(c) flank (d) face [ESE : 1998] 2. They are difficult to manufacture.
D
3. Standardization is not possible.

5.17 Consider the following characteristics: 4. The cost of production is low.
A. Small interference Which of these statements are correct?
B. Strong tooth (a) 1, 2 and 3 (b) 1, 2 and 4
A
C. Low production cost (c) 2, 3 and 4 (d) 1, 3 and 4

D. Gear with small number of teeth [ESE : 1999]

M
Answers Gear and Gear Train

5.1 (d) 5.2 (b) 5.3 (a) 5.4 (d) 5.5 (a) 5.6 (d) 5.7 (d) 5.8 (a)
5.9 (a) 5.10 (c) 5.11 (d) 5.12 (b) 5.13 (d) 5.14 (c) 5.15 (a) 5.16 (d)
5.17 (d) 5.18 (d) 5.19 (b) 5.20 (a)
Explanations Gear and Gear Train
5.1 (d) 5.2 (b)

When N coincide with O, Then θ = 90°, i.e. ⎛ω ⎞
2
acceleration is maximum and velocity is zero. I′B = IB(on B) × ⎜ B ⎟ = n2I2

⎝ ωA ⎠
5.3 (a) TA
⇒ y= x
B
Due to slip present, the velocity ratio will not
50
remain constant and hence, belt drive is not a ⇒ 1= x
positive drive. 200
⇒ x=4
5.4 (d) Revolution of gear A,
For involute gears, pressure angle is always NA = x + y
constant. This 14.5° to 22.5°. The general value = 1 + 4 = 5 Revolution
being 20°.
5.8 (a)
Y
5.5 (a)
Interference occurs between tip of the gear tooth
In reverted gear train, first and last gear is on the and flank of pinion.
same axis. Such an arrangement has application
S
on speed reducers, clocks (to connect hour hand 5.9 (a)
to minute hand) and machine tools. For compound gear train
5.6 (d) Product of no. teeth on driven

Speed ratio =
A
Product of no of teeth on driver
To avoid interference certain minimum number of
teeth must be provided on the gear. 40 × 70 × 50
= =8
20 × 35 × 25
Arc of contact
contact ratio =
Circular pitch
E
5.10 (c)
Lewis equation gives static load on teeth. Speed ratio of compound gear train
5.7 (d) Product of no. of teeth on driven
=
Product of no. of teeth on driver
E
Activities NA Ns Arm
1. Fix the Arm C − − 0 5.11 (d)
T
2. Give +1 Revolution +1 − A 0 (1) Parallel shafts with slight offset → oldham
TB
D
coupling
to gear A
(2) Parallel shafts at reasonable distance → Belts
TA
3. Give + x Revolution + x − x 0 and pulleys
TB
(3) Perpendicular shafts → worm and wheel
A
to same gear (A)

TA
(4) Intersecting shafts → Hooks joint
4. Give +y Revolution x + y y− x y
TB
5.12 (b)
to Arm C
M
Reverted gear train is a special type of compound

Revolution of Arm, y = 1 gear train in which the first and the last gear have
Gear B (TB = 200) fixed, the same axis. i.e. they are coaxial.
i.e. NB = 0
5.13 (d)
A B
Involute starts from base circle.
C Two important properties of an involute
– + TA = 50
Arm TB = 200 (i) A normal to an involute is a tangent to the
base circle.
(ii) The radius of curvature of an involute is equal
TA to the length of the tangent to the base circle.
⇒ y– x =0
TB
5.14 (c) 5.18 (d)

Spiral gears are also called as skew gears, screw
B gears or crossed helical gears. In helical gears,
the power is transmitted between two parallel
shafts. In spiral gears (cross helical gears) the
C
power is transmitted between two non-parallel and
A non-intersecting shafts. Spiral gears give a point
contact. Due to point contact, spiral gears are
not recommended for power transmission. Spiral
Y
Given: TA = 100, TB = 20, Narm‘c’ = 3 rev. gears are used in instrumentation, distribution
NA = 0 (∵ A is fixed) device of automobile engine and other similar
To find: NB = ? application where there are small loads.
The mating gears in helical gearing must have
S
Condition Arm - C Gear - A Gear - B
opposite hand of helix, but is case of spiral gearing,
Suppose arm C 0 +1 T
– A the same or opposite hand of helix can be meshed.
is fixed and gear TB
A
A is given +1 5.19 (b)
rev. CCW. θ = 14.5°, Z = 48, d = 288 mm
Arm'C 'is fixed 0 +x T
−x A d 288
and gear A is TB Module = = = 6 mm
z 48
given +x rev.
E
circular pitch = πm = 6π = 18.85 mm
CCW addendum = m = 6 mm
Add + y rev. y y +x TA
y –x 1 1
TB diametral pitch = =
m 6
E
According to the question
5.20 (a)
y = 3
y+x = 0 It has been proved that any arbitrary shape of the
x = –3 tooth can be chosen for profile of teeth of one of
D
TA the two gears in mesh and profile for the other

NB = y − x
TB may be determined to satisfy the law of gearing.
Such teeth are called conjugate teeth.
100
3+3× = 18 revolutions Theoretically, such profile teeth will transmit the
A
20
desired motion but objection to such random
5.16 (d)
profile is the obvious difficulty of manufacture,
standard-ization and cost of production. Therefore,
M
ce conjugate teeth are not in normal use.

Fa
Addendum k
an
Fl
Pitch circle
Dedendum
5.17 (d)
Characteristics of stub 20° involute system
1. Small interference
2. Strong tooth
3. Low production cost
4. Gear with smaller number of teeth.
6 Flywheel
6.1 The given figure shows the output torque plotted (a) positive throughout
Y
against crank positions for a single cylinder four- (b) negative throughout
stroke-cycle engine. The areas lying above the (c) positive during major portion of the stroke
zero-torque line represent positive work and the (d) negative during major portion of the stroke
areas below represent negative work. The engine [ESE : 1996]
S
drives a machine which offers a resisting torque
6.3 In the case of a flywheel, the maximum fluctuation
magnitudes of the hatched areas are given by
of energy is the
number (in the areas) as shown :
(a) sum of maximum and minimum energies
A
Avg. torque
(b) difference between the maximum and
+49
minimum energies
+43 +36 (c) ratio of the maximum and minimum energy
A B C D E F G (d) ratio of the minimum and maximum energy
E
Output toruqe
H
[ESE : 1998]
6.4 Consider the following parameters:

1. Limit of peripheral speed
180° 360° 540° 720° 2. Limit of centrifugal stress
0°
E
Crank position 3. Coefficient of fluctuation of speed
4. Weight of the rim
During the cycle, the minimum speed occurs in Which of these parameters-are used in the
the engine at
D
calculation of the diameter of flywheel rim?

(a) B (b) D (a) 1, 3 and 4 (b) 2, 3 and 4
(c) H (d) F [ESE : 1995] (c) 1, 2 and 3 (d) 1, 2 and 4
6.2 In a 4-stroke IC engine, the turning moment during [ESE : 1999]
A
the compression stroke is

Answers Flywheel
M
6.1 (d) 6.2 (b) 6.3 (b) 6.4 (d)
Explanations Flywheel
6.1 (d) Energy at E = E + 100 – 75 + 49 – 77 + 43
Let energy at H is E = E + 40
Energy at A = E + 100 Energy at F = E + 100 – 75 + 49 – 77+43–77
Energy at B = E + 100 – 75 = E + 25 = E – 33
Energy at C = E + 100 – 75 + 49 Energy at G = Energy at F + 36
= E + 74 = E – 33 + 36
Energy at D = E + 100 – 75 + 49 – 77 =E+3
=E– 3 Minimum energy at F. Hence speed at F will be
minimum
6.2 (b) 6.4 (d)

4-stroke IC engine Linear velocity
For a given ‘ω’ more the diameter more will be V
Crank angle (θ)

moment (T)
Centrifugal stress (σ)

Turning
V=
Density of rim (ρ)
π 2π 3π 4π ∴ For calculation of flywheel rim
Suction Comp. Exhaust 1. Limit of peripheral speed
Expansion 2. Limit of centrifugal stress
3. Weight of rim.
Y
6.3 (b)
1 2 2
emax = KEmax – KEmin = I (ωmax − ωmin)
2
S
A
E
E
D
A
M
7 Vibration
7.1 The equation of free vibrations as a system is

X&& + 36π2 x = 0 . Its natural frequency is
Y
k
(a) 46 Hz (b) 3π Hz 1. k 2.
(c) 3 Hz (d) 6π Hz
k
[ESE : 1995]
S
7.2 Which of the following methods can be used to m m
x x
determine the damping of machine element?
A
1. Logarithmic method (a) N/2 (b) N / 2
2. Bandwidth method
(c) 2 /N (d) 2N [ESE : 1995]
3. Rayleigh method
4. Holzer method 7.6 When shaking force is transmitted through the
E
Select the correct using the codes given below: spring, damping becomes detrimental when the
(a) 1 and 3 (b) 1 and 2 ratio of its frequency to the natural frequency is
(c) 3 and 4 (d) 1, 3 and 4 greater than
[ESE : 1995] (a) 0.25 (b) 0.50
E
(c) 1.00 (d) 2 [ESE : 1996]
7.3 If ω / ωn = 2, where ω is the frequency of
excitation and ω n is the natural frequency of 7.7 When the mass of a critically damped single
vibrations, then the transmissibility of vibrations degree of freedom system is deflected from its
D
will be equilibrium position and released, it will

(a) 0.5 (b) 1.0 (a) return to equilibrium position without oscillation
(c) 1.5 (d) 2.0 (b) oscillate with increasing time period
A
[ESE : 1995] (c) oscillate with decreasing amplitude

7.4 A slender shaft supported on two bearing at its (d) oscillate with constant amplitude
ends carries a disc with a eccentricity ‘e’ from the [ESE : 1996]
M
axis of rotation. The critical speed of the shaft is 7.8 The equation of motion for a single degree of
N. If the disc is replaced by a second one of freedom system with viscous damping is
same weight but mounted with an eccentricity 2e,
4 X&& + 9 X& + 16 X = 0 the damping ratio of the
critical speed of the shaft in the second case is
system is
(a) 1/2 N (b) 1/ 2 N 9
9
(a) (b)
(c) N (d) 2 N 128 16
[ESE : 1995]
9 9
(c) (d)
7.5 For the spring mass system shown in the figure 1, 8 2 8
the frequency of vibration is N. What will be the [ESE : 1996]
frequency when one more similar spring added
in series, as shown in figure 2?
7.9 For the spring mass system shown in the given

figure, the frequency of oscillations of the block A
along the axis of the spring is x
x sin f
k1 k2
O ϖnt
m
1 k1 − k 2 1 k1k 2 The envelope A has the equation :

(a) (b) (a) X e–t
2π 2 π (k1 + k2 )m
Y
m
(b) X sin ( 1 − ζ2 )ωn t
– ζω t
1 k1 + k 2 1 m (c) e n
(c) (d) 2 π k + k
2π m 1 2 (d) X e −ζωn t [ESE : 1997]
S
[ESE : 1996]
7.13 Which is the equivalent stiffness (i.e. spring constant)
7.10 The critical speed of a rotating shaft depends upon the system shown in the given figure?
A
(a) mass
(b) stiffness 10 Coil
k1= 8 N/mm
(c) mass and stiffness
(d) mass, stiffness and eccentricity
E
[ESE : 1996]
5 Coil
k2= 16 N/mm
List-I
(a) 24 N/mm (b) 16 N/mm
E
A. Flywheel (c) 4 N/mm (d) 5.3 N/mm
B. Governor [ESE : 1997]
C. Critical speed
7.14 The given figure depicts the vector diagram of
D
D. Inertia Force
List-II forces and displacements in the case of Forced
1. Dunkerley method Damped Vibration. If vector A represents the
2. Turning moment forcing function P = P 0 sinω t , vector B the
A
displacement y = Ysinωt and φ the phase angle

3. D’Alembert’s Principle
between them, then the vectors C and D represent
4. Speed control on par with load
respectively
Codes:
ω
M
A B C D A B
(a) 4 2 3 1
(b) 4 2 1 3
φ
(c) 2 4 3 1
(d) 2 4 1 3
C
[ESE : 1997] O
7.12 A damped free vibration is expressed by the D

general equation (a) the force of inertia and the force of damping
x = X e −(ζωnt) sin ( 1 – ζ ω t + φ)
2
n
(b)
(c)
the elastic force and the damping force
the damping force and the inertia force
which is shown graphically below : (d) the damping force and the elastic force
[ESE : 1997]
7.15 If two identical helical spring are connected in (c) a hyperbolic curve
parallel and to these two, another identical spring (d) a linear curve [ESE : 1998]
is connected in series and the system in loaded
7.18 The critical speed of a uniform shaft with a rotor
by a weight W, as shown in the figure, then the
at the centre of the span can be reduced by
resulting deflection will be given by (δ = deflection,
(a) Reducing the shaft length
S = stiffness, W = load)
(b) Reducing the rotor mass
3W W
(a) δ = (b) δ = (c) Increasing the rotor mass
2S 2S (d) Increasing the shaft diameter [ESE : 1998]
2W W
(c) δ = (d) δ =
Y
3S 3S 7.19 If a mass ‘m’ oscillates on a spring having a mass
ms and stiffness ‘k’, then the natural frequency of
the system is given by
S S
S
k k
(a) m (b) m
m+ s + ms
3 3
S
A
3k k
(c) m + ms (d) m + ms
W
[ESE : 1997] [ESE : 1998]

E
7.16 Two heavy rotating masses are connected by 7.20 Match List-I with List-II and select the correct
shafts of length l1, l2 and l3 and the corresponding answer using the codes given below the lists:
diameters are d1, d2, d3 . This system is reduced List-I
to a torsionally equivalent system having uniform A. Node and mode
B. Equivalent inertia
E
diameter d1 of the shaft. The equivalent length of
the shaft is equal to C. Log decrement
(a) l1 + l2 + l3 D. Resonance
List-II
l1 + l2 + l3
D
(b) 1. Geared vibration

3 2. Damped-free vibration
3 3 3. Forced vibration
⎛d ⎞ ⎛d ⎞
(c) l1 + l2 ⎜ 1 ⎟ + l3 ⎜ 1 ⎟ 4. Multi-rotor vibration
A
⎝ d2 ⎠ ⎝ d3 ⎠
Codes:
4 4
⎛d ⎞ ⎛d ⎞ A B C D
(d) l1 + l2 ⎜ 1 ⎟ + l3 ⎜ 1 ⎟ [ESE : 1997]
⎝d ⎠ 2 ⎝d ⎠ 3 (a) 1 4 3 2
M
(b) 4 1 2 3
7.17 The amplitude versus time curve of as damped-
(c) 1 4 2 3
free vibration is shown in the below figure. Curve
(d) 4 1 3 2
labelled ‘A’ is
[ESE : 1998]
Curve A
7.21 The critical speed of a uniform shaft with a rotor
X1
Amplitude
at the centre of the span can be reduced by

(a) reducing the shaft length
Time (b) reducing the rotor mass
(c) increasing the rotor mass
tp tp
(d) increasing the shaft diameter
(a) a logarithmic decrement curve
[ESE : 1998]
(b) an exponentially decreasing curve
7.22 A rotating shaft carries a flywheel which overhangs (c) slightly greater than natural frequency
on the bearing as a cantilever. If this flywheel (d) zero
weight is reduced to half of its original weight, [ESE : 1999]
the whirling speed will
7.25 The value of the natural frequency obtained by
(a) be double
Rayleigh’s method
(b) increase by 2 times
(a) is always greater than the actual fundamental
(c) decrease by 2 times
frequency
(d) be half
(b) is always less than the actual fundamental
[ESE : 1999]
frequency
Y
7.23 If a spring-mass-dashpot system is subjected to (c) depends upon the initial deflection curve
excitation by a constant harmonic force, then at chosen and may be greater than or less than
resonance, its amplitude of vibration will be the actual fundamental frequency
S
(a) infinity (d) is independent of the initial deflection curve
(b) inversely proportion to damping chosen
(c) directly proportional to damping [ESE : 1999]
(d) decreasing exponentially with time
A
7.26 In a multi-rotor system of torsional vibrations,
[ESE : 1999] maximum number of nodes that can occur is
7.24 In a forced vibration with viscous damping, (a) two
maximum amplitude occurs when forced (b) equal to the number of rotors plus one
E (c) equal to the number of rotors
frequency is
(a) equal to natural frequency (d) equal to the number of rotors minus one
(b) slightly less than natural frequency [ESE : 1999]

E
Answers Vibration
7.1 (c) 7.2 (b) 7.3 (b) 7.4 (c) 7.5 (b) 7.6 (d) 7.7 (a) 7.8 (b) 7.9 (c)
7.10 (c) 7.11 (d) 7.12 (d) 7.13 (a) 7.14 (d) 7.15 (a) 7.16 (d) 7.17 (b) 7.18 (c)
D
7.19 (a) 7.20 (b) 7.21 (c) 7.22 (b) 7.23 (b) 7.24 (b) 7.25 (a) 7.26 (d)
Explanations Vibration
A
7.1 (c) 7.4 (c)
1 Critical speed of shaft is independent of the

f= 36π 2 = 3 Hz. eccentricity.
2π
M
7.3 (b) 7.5 (b)
ω k W
For = W′ = = n
2 transmissibility is 1 2m 2
ωn
N
N′ =
2
7.6 (d)
ω
The damping is detrimental for < 2
ωn
TR
ω
1 2 and advantageous only in the region > 2.
Frequency ratio ωn
7.7 (a) Vector representation of forces on the system having

forced vibration
Critically damped system are of special interest
The correct option is (d) i.e., vector (c) and (d)
as they regain their equilibrium position, in the
represent the damping force and the elastic force.
shortest possible time, without oscillation. For this
reason, large guns are provided with dashports The following points are observed from the vector
having critical value of damping. diagram:
1. The displacement lags the impressed force
7.8 (b) an angle φ.
m &&
x + c x& + k x = 0 2. The spring force is always opposite in direction
∴ m = 4; c = 9. k = 16
Y
to the displacement.
C 9 9 3. The damping force lags the displacement by
∴ξ= = =
2 km 2 4 × 16 16 90°. Since the velocity leads the displacement
by 90°, it follows that the damping force is
S
7.9 (c)
always in direction to the velocity.
Both spring are connected is parallel
4. The inertia force is an phase with the
keq = k1 + k2
displacement, therefore the inertia is always
A
1 k1 + k 2 opposite in direction to the acceleration.
f=
2π m
7.15 (a)
7.10 (c) 2S × S 2
E keq = = S
2S + S 3
k
ω= 2
m ∴W= S ×δ
3
7.11 (d) 3W
∴δ=
E
1. Flywheel → Turning moment 2S
2. Governor → speed control on par with load
3. Critical speed → Dunkerley method 7.16 (d)
4. Inertia force → D’ Alembert’s principal If the two shafts are equivalent, then the stiffness
D
is same and hence, the total angle of twist should

7.12 (d) be the same (The above analysis can also be
−ξω t
Equation for envelope ‘A’ is given as X e n done by considering the shaft as springs in
A
series)
7.13 (a) θ = θ1 + θ2 + θ3
Springs are connected in parallel
MT GJ
∴ keq = K1 + K2 = 8 + 16 = 24 N/mm We know that =
θ
M
L
7.14 (d)
MT L
∴θ=
GJ
Perpendicular
MT L MT L1 MT L2 MT L3
axis
= + +
A
GJ GJ1 GJ2 GJ3
g for
ce F0 L L1 L2 L3 ⎛ π 2⎞
sprin x x = J + J + J ⎜⎝ J = d ⎟
k
φ J 1 2 3 32 ⎠
ωt Reference axis
cωx 4 4
damping 2x ⎛ d1 ⎞ ⎛ d1 ⎞
force mω L = L1 + L2 ⎜ ⎟ + L3 ⎜ ⎟
a ⎝d ⎠ ⎝d ⎠
Inerti 2 3
force
L
7.17 (b) 1 1 x& 2y 2
= m x& 2 + ∫ ρ 2 dy
The damping factor such that the vibration motion 2 20 L
is allowed, however, the amplitude of motion L
1 1 ρx 2
2 L2 ∫0
reduce with time in an exponential manner. = m x& 2 + y 2dy
2
7.18 (c)
1 1 1 1
ρLx& 2 = m x& +
2
= &2 + m x& 2
k 2 mx 6 2 6 s
ωn = m ↑, ωn ↓
m x& 2 ⎛ m ⎞
= ⎜ m+ s⎟
2 ⎝ 3 ⎠
Y
7.19 (a)
U = PE + KE
o
o
1 x& 2 ⎛ m ⎞
= k &
x 2
+ ⎜ m+ s⎟
y 2 2⎝ 3⎠
S
dy
δ Differentiating and using energy method, we get
ms
du 2 ⎛ ms ⎞ 2
= x& &&
x ⎜m + ⎟ + k xx& = 0
A
m x dt 2 ⎝ 3 ⎠ 2
k
Let ‘L’ be the length of the spring and let ‘ρ’ be ∴ &x& + x=0
⎛ ms ⎞
the mass of spring per unit length. ⎜⎝ m + 3 ⎟⎠
E
Mass of spring Ms = PL
Consider a small element ‘dy’ of the spring at a k
∴ ωn =
distance ‘y’ from the support. The mass of element ⎛ ms ⎞
⎜⎝ m + 3 ⎟⎠
is dms.
dms = ρdy
E
Considering that the free end of the spring has 7.20 (b)
moved by ‘x’. The displacement at the fixed point (1) Node and mode → Multi-rotor vibration
will be zero. From similar triangle at any point, at
D
(2) Equivalent Inertia → Geared vibration

a distance ‘y’ the displacement is given by ‘δ’
such that (3) Log decrement → Damped free vibration
δ x (4) Resonance → Forced vibration
=
A
y L
7.21 (c)
xy
∴ δ =
L k
ωn =
Hence velocity of dms will be ‘ δ& ’ m
M
x&y 1
∴ ωn ∝
δ& = L m
The kinetic energy of the system will be due to
7.22 (b)
mass of the spring ‘ms’ and the hanging mass m.
KE = KEspring + KEmass 1
Whirling sheed ∝
L
1 1 I
∫ dms δ2 + m x&
2
=
2 2 ω2 2I
0
∴ =
2 ω1 I
⎛ x&y ⎞
L
1 1
=
2
m x& 2 + ∫
2 0
ρdy × ⎜ ⎟
⎝ L⎠ ω2 = 2ω1
7.23 (b) Where Mi and yi are the mass and the deflection
at point i.
At resonance, amplitude of vibration will be
In case the deflection curve assumed in (i) above
(F0 / k ) / 2ξ hence inversely proportional to
is due to the load considered as dead or static,
damping. as is generally done to start with, then the natural
frequency obtained from eq. (i) will be somewhat
7.24 (b)
higher than the actual value. The reason is that
In a forced vibration with viscous damping, during the actual vibrations the deflection curve
maximum amplitude occurs when forced will be due to the inertia load rathers than static
Y
frequency is slightly less than natural frequency. loads, and thus the assumed deflection will be
F0 different from the actual deflection and wherever
A =
(s − m ω 2 ) + (c ω)2 assumed deflection is different from the actual
one, a higher frequency will result. This is because
S
F0 /s
A = any change of deflection curve from the actual is
⎡ ⎛ ω ⎞2 ⎡ ω⎤ ⎤
2
⎢1 − ⎜ associated with the stiffening of system which
+ ⎢2 ε ⎥ ⎥
⎢ ⎝ ωn ⎟⎠ ⎣ ωn ⎦ ⎥⎦ results in a higher natural frequency.
⎣
A
7.25 (a) 7.26 (d)
The correct option is (a) In a multi-rotor system of torsional vibrations,

maximum number of nodes that can occur is
E
Rayleigh method is used for finding the first
equal to the number of rotors minus one.
natural frequency of a multi-degree of freedom
system
g ΣM i y i
ωn2 = ...(i)
ΣM i y i 2
E
D
A
M
8 Governors
8.1 For a spring controlled governor to be stable, the 8.4 Assertion (A): The degree of hunting with an
Y
controlling force (F) is related to the radius (r) by unstable governor will be less than that with an
the equation isochronous governor.
(a) F = ar – b (b) F = ar + b Reason (R): With an unstable governor, once the
(c) F = ar (d) F = a/r+b sleeve has moved from one extreme position to
S
[ESE : 1995] the other, a finite change of speed is required to
cause it to move back again.
8.2 Which one of the following equation is valid with (a) both A and R are true and R is the correct
reference to the given figure. A explanation of A
A
⎛W ⎞ ⎛ g ⎞ explanation of A
(a) ω 2 = ⎜ ⎟ ⎜ ⎟
⎝w ⎠ ⎝h⎠ h (c) A is true but R is false
(d) A is false but R is true [ESE : 1997]
2 ⎛W + w ⎞ ⎛ g⎞
1/2
B
E
(b) ω = ⎜
⎝ w ⎟⎠ ⎜⎝ h ⎟⎠ 8.5 The sensitivity of an isochronous governor is
w
(a) zero (b) one
1/2
2 ⎛ w ⎞ ⎛ g⎞ W (c) two (d) infinity [ESE : 1997]
(c) ω = ⎜
⎝ W + w ⎟⎠ ⎜⎝ h ⎟⎠
8.6 Give that
E
2 ⎛W + w ⎞ ⎛ g ⎞ m = mass of the ball of the governor

(d) ω = ⎜⎝ C
w ⎟⎠ ⎜⎝ h ⎟⎠ ω = angular velocity of the governor and
[ESE : 1996] g = acceleration due to gravity, the height of
D
Watt’s governor is given by

g g
answer using the codes below the lists: (a) (b)
2ω 2 ω2
List-I
A
A. Hunting 2g 2g
(c) (d)
B. Isochronism ω 2
ω2
C. Stability [ESE : 1998]
D. Effort
8.7 For a given fractional change of speed, if the
M
List-II displacement of the sleeve is high, then the

1. One radius rotation for each speed. governor is said to be
2. Too sensitive. (a) hunting (b) isochronous
3. Mean force exerted at the sleeve during (c) sensitive (d) stable [ESE : 1998]
change of speed.
4. Constant equilibrium speed for radii of 8.8 Consider the following speed governors :
rotation. 1. Porter governor 2. Hartnell governor
3. Watt governor 4. Proell governor
Codes:
The correct sequence of development of these
A B C D
governors is
(a) 2 4 1 3
(a) 1, 2, 3, 4 (b) 3, 1, 4, 2
(b) 3 1 4 2
(c) 2 1 4 3 (c) 3, 1 2, 4 (d) 1, 3, 4, 2
(d) 1 2 3 4 [ESE : 1996] [ESE : 1999]
8.9 Consider the given figure: and h, the masses of balls used in the Proell
governor are less than those of ball used in the
Porter governor.
Reason (R): The ball is fixed to an extension link
h Proell governor.
Of these statements:
explanation of A
ω
explanation of A
Y
W
Assertion (A): In order to have the same [ESE : 1999]
S
equilibrium speed for the given values of ω , W
Answers Governors
A
8.1 (a) 8.2 (d) 8.3 (a) 8.4 (d) 8.5 (d) 8.6 (b) 8.7 (c) 8.8 (b) 8.9 (a)
Explanations Governors
⇒ K=1
8.1 (a)
E
ω +W ⎤
F = ar + b → unstable governor ω2 = g ⎡
F = ar → isochronous governor h ⎢⎣ ω ⎥⎦
F = ar – b → stable governor 8.3 (a)
1. Hunting : Too sensitive
E
2. Isochronism : Constant equilibrium speed for

Controlling force
radius of rotation
e
bl
ta
3. Stability : One radius rotation for each speed

s
ns
ou
U
D
on
4. Effort : Mean force exerted at the sleeve

hr
oc
le
Is
during change of speed

ab
St
8.4 (b)
A
The correct option is (b) i.e., both A and R are

Radius of rotation true and R is correct explanation of A.
8.2 (d) Whenever there is a change in the mean speed,
M
Porter governor centrifugal governor develop a tendency to

oscillate around the derived new mean position.
This is because of the fact that when there is a
h h θ change in the load on the engine, with a
β consequent change is engine speed, the
ω W
governor balls and the sleeve seek a new position
to restore the original speed. However, due to
g ⎡ 2ω + W (1 + k ) ⎤ inertia they overshoot the mark and thereafter
ω2 =
h ⎢⎣ 2ω ⎥
⎦ again move towards the derived position in the
tan β opposite direction with the same result. The
Where K= process is than repeated and oscillation are set
tan θ
In this case β = θ up. If the frequency of fluctuations in engine
speed happens to coincide with the natural 8.7 (c)

frequency of oscillations of the governor, then due
A governor in said to be sensitive if the
to resonance, the amplitude of oscillation
displacement of the sleeve is high for a given
becomes very high, with the result that the
fractional change of speed
governor tends to intensity the speed variation
instead of controlling it. Such a situation is known
N1 + N2
Sensitivity =
as hunting. 2(N1 − N2 )
The problem of hunting becomes more acute 8.8 (b)

when the sensitiveness of a governor is high i.e.,
Correct sequence of development of governors.
Y
when a change in speed causes a large sleeve
1. Watt 2. Porter 3. Proell 4. Hartnel
movement. For example an isochronous governor
(i.e., one that is infinitely sensitive) will oscillate 8.9 (a)
between the highest and the lowest position if
S
the speed deviates from the isochoronous speed.
h
8.5 (d) ω
A
N1 + N2 a
Sensitivity (e) = W
2(N1 − N 2 )
For isochronous governor ; N1 = N2 w — weight of ball
∴ e=∞ W — weight of sleeve
E ω — angular speed
8.6 (b) Porter governor
g ⎡w + W ⎤
ω2 =
θ h ⎢⎣ w ⎥⎦
E
α Proell
h
ω h
ω
D
2 r e
mrω
a
W
Mg
r ω2
A
∴ tanθ = r/h = g ⎛ a ⎞ ⎡w + W ⎤
ω2 =
g h ⎜⎝ e ⎟⎠ ⎢⎣ w ⎥⎦
g
∴ h= For the given values of ω, W and h the masses of
ω2
M
balls used in proell generator are less than those

of ball used is porter generator.

9 Balancing and Gyroscope
9.1 A rotor supported at A and B, carries two masses

W
Y
as shown in the given figure. The rotor is
e
m
a
R
A B
S
W
L
R
A
W 2 a
m (a) Zero (b) ω e
g L
(a) dynamically balanced
(b) statically balanced W 2 a W 2 L
(c) 2 ωe (d) ω e
g L g a
(c)
E
statically and dynamically balanced
(d) not balanced [ESE : 1997]
[ESE : 1995]
9.5 A four-cylinder symmetrical in-line engine is shown
9.2 A system of masses rotating in different parallel in the below figure, Reciprocating weights per
planes is in dynamic balance if the resultant cylinder are R1 and R2, and the corresponding
E
(a) force is equal to zero angular disposition of the crank are α and β.
(b) couple is equal to zero Which one of the following equations should be
(c) force and the resultant couple are both equal satisfied for its primary force balance?
D
to zero
(d) force is numerically equal to the resultant
1 3
couple, but neither of them need necessarily 3
1 R1 a1 a2 R2
be zero β α
A
[ESE : 1996] β α
4 a1
2 R2 R1
9.3 When the primary direct crank of a reciprocating 2 4
engine positioned at 30° clockwise, the secondary
M
reverse crank for balancing will be at (a) a1tan α = a2 tan β

(a) 30° anticlockwise (b) cos α = 1/2 sec β
(b) 60° anticlockwise (c) R1a1sin 2α = –R2a2sin 2β
(c) 30° clockwise (d) R1cos α = R2cos β
(d) 60° clockwise [ESE : 1998]
[ESE : 1997]
9.6 The primary disturbing force due to inertia of
9.4 A statically-balanced system is shown in the given reciprocating parts of mass m at radius r ,
figure. Two equal weights W , each with an revolving with an angular velocity ω is given by
eccentricity e, are placed on opposite sides of (a) mω2rsin θ (b) mω2rcos θ
the axis in the same axial plane. The total dynamic (c) mω rsin (2θ/n)
2 (d) mω2rcos (2θ/n)
reactions at the supports will be [ESE : 1999]
9.7 If a two-mass system is dynamically equivalent (c) secondary unbalanced forces will increase
to a rigid body, then the system will NOT satisfy (d) secondary unbalanced forces will decrease
the condition that the [ESE : 1999]
(a) sum of the two masses must be equal to that
9.9 Assertion (A): In locomotive engines, the
of the rigid body
reciprocating masses are only partially balanced.
(b) polar moment of inertia of the system should
Reason R): Full balancing might lead to lifting
be equal to that of the rigid body
the locomotive engine off the rails.
(c) Centre of Gravity (CG) of the system should
coincide with that of the rigid body
explanation of A
(d) total moment of inertia about the axis through
Y
CG. Must be equal to that of the rigid body
explanation of A
[ESE : 1999]
9.8 If the ratio of the length of connecting rod to the (d) A is false but R is true
S
crank radius increases, then [ESE : 1999]
(a) primary unbalanced forces will increase

(b) primary unbalanced forces will decrease
A
Answers Balancing and Gyroscope
9.1 (b) 9.2 (c) 9.3 (b) 9.4 (a) 9.5 (d) 9.6 (b) 9.7 (b) 9.8 (d) 9.9 (a)
Explanations Balancing and Gyroscope
E
9.1 (b) 9.4 (a)
For statically balanced rotor
r W
ΣF = 0
E
e
For dynamically balanced rotor A B
r a
Σ F =0, ΣM = 0
But in this case ΣM ≠ 0 only ΣF = 0 therefore the
D
W
rotor is statically balanced.
L
9.2 (c)
Moment about A
A
For dynamic balance, resultant force and resultant

couple are equal to zero. W 2 (L − a) W 2 (L + a)
⇒ eω × – eω
ΣF = 0 g 2 g 2
ΣM = 0 + RB × L = 0
M
W eω 2
9.3 (b) L × RB = [L + a – (L – a)]
g 2
When the primary direct crank of a reciprocating
W a a
engine positioned at 30° clockwise, the secondary RB = eω2 = me ω 2 ×
g L L
reverse crank for balancening will be at 60°
W 2a
anticlockwise. RA = eω
g L
Total dynamic force (magnitude)
= RA + RB
2W 2 a
= eω
g L
9.5 (d) 9.7 (b)
Following condition must be satisfied by two

R1 mass system for dynamic equilibrium
α (i) The mass of two system has to be the same.
R2
β
(ii) The centre of gravity of the two system has
to fall at the same position.
(iii) The moment of inertia of the two system must
β
be the same.
R2
Y
α Then the three condition stated above lead to
R1
the following mathematical equation
m1 + m2 = m
S
m1a = m2b
The correct option is (d) m1 a2 + m2b2 = mk2
Balancing horizontal force let radius be x
A
9.8 (d)
R1x cos α + R1x cos α – R2x cos β – R2x cos β = 0
FP = Primary unbalanced force = mrω2cosθ
2R1x cos α – 2R2x cos β = 0
Fs = Secondary unbalanced force
∴ R1cos α = R2 cos β
E
mr ω2 ⎛ l⎞
9.6 (b) = cos2θ ⎜⎝ n = ⎟⎠
n r
⎡ cos 2θ ⎤
Funbalanced force = mr ω 2 ⎢cos θ +
⎣ n ⎥⎦ 9.9 (a)
E
2 In locomotive engines, the reciprocating masses
2 mrω cos 2θ
mrω cos θ n are only partially balanced because full balancing
=
might lead to lifting the locomotive engine off the
D
Primary unbalanced Secondary unbalanced rails, because of hammer blow.

force force

A
M
10 Miscellaneous
10.1 Given figure shown a flexible shaft of negligible K

(a)
Y
mass of torsional stiffness k coupled to a viscous K +C
damper having a coefficient of viscous damping 1
C. If at any instant the left and right ends of this (b) C
shaft have angular displacement θ1 and θ 2 1+ s
K
S
respectively, then the transfer function θ2/θ1 of 1
the system is (c)
K
1+ s
C
A
K
(d) 1 + s
K C
[ESE : 1995]
θ1 θ2
E
C
Answers Miscellaneous
E
10.1 (b)
D
A
M
UNIT
IV
Y
Design of Machine Elements
S
Syllabus
A
Design for static and dynamic loading; failure theories; fatigue strength and the S-N diagram; principles of the
design of machine elements such as riveted, welded and bolted joints. Shafts, Spur gears, rolling and sliding contact
bearings, Brakes and clutches.
E
E
Contents
D
1. Theories of Failure (Static & Dynamic) ................................................................................ 75

A
2. Bolted, Riveted and Welded Joint ..................................................................................... 78
3. Bearings, Shafts, Axles & Keys ......................................................................................... 81

M
4. Gears ................................................................................................................................. 87
5. Brakes, Clutches and Ropes ............................................................................................. 88
6. Power Screws ..................................................................................................................... 89
7. Helical Springs ................................................................................................................... 91
8. Miscellaneous .................................................................................................................... 94

1 Theories of Failure
(Static & Dynamic)
1.1 The design calculations for members subject to (a) In Ductile material local yielding may
Y
fluctuating loads with the same factor of safety distribute stress concentration
yield the most conservative estimates when using (b) Ductile material have large Young’s modulus
(a) Gerber relation (c) Poisson’s ratio is larger in ductile materials
(b) Soderberg relation (d) Modulus of rigidity is larger in ductile material
S
(c) Goodman relation [ESE : 1996]
(d) None of the above
1.6 Match List-I (Failure theories) with List-II (Figures
[ESE : 1995]
representing boundaries of these theories) and
A
1.2 Permissible bending moment in a circular shaft select the correct answer using codes given below
under pure bending is M according to maximum the lists:
principal stress theory of failure the permissible List-I
bending moment in the same shaft is
E A. Maximum Principal stress theory
(a) 1/2 M (b) M B. Maximum shear stress theory
(c) (d) 2 M C. Maximum octahedral shear stress theory
M
D. Maximum shear strain energy theory
[ESE : 1995]
List-II
E
1.3 If shaft made from ductile material is subjected σ2
to combined bending and twisting moments.
Calculations based on which one of the following
failure theories would give the most conservative σ1
D
1.
value?
(a) Maximum principal stress theory
(b) Maximum shear stress theory σ2
A
(c) Maximum strain energy theory

(d) Maximum distortion energy theory
2. σ1
[ESE : 1996]
M
1.4 If the size of a standard specimen for fatigue

testing machine is increased the endurance limit σ2
for the material will
(a) have same value as that of standard σ1
specimen 3.
(b) increases
(c) decreases
σ2
(d) none of these
[ESE : 1996]
σ1
1.5 Stress concentration in a machine component of 4.
ductile materials not so harmful as it is in brittle
material because
Codes:
σ2/σyp
A B C D
(a) 2 1 3 4
(b) 2 4 3 1
(c) 4 2 3 1 (a) σ1/σyp
(d) 2 4 1 3
[ESE : 1997]
1.7 According to the maximum shear stress theory σ2/σyp

of failure, permissible twisting moment in a circular
Y
shaft is T. The permissible twisting moment in
the same shaft as per the maximum principal
(b) σ1/σyp
stress theory of failure will be
S
(a) T/2 (b) T
(c) 2T (d) 2T
σ2/σyp
[ESE : 1998]
A
1.8 A solid circular shaft is subjected to pure torsion.
The ratio of maximum shear stress to maximum
(c) σ1/σyp
normal stress at any point would be
(a) 1 : 1 (b) 1 : 2
E
(c) 2 : 1 (d) 2 : 3
σ2/σ yp
[ESE : 1999]
1.9 Which one of the following figures represents the

maximum shear stress Theory or Tresca criterion?
E
(d) σ1/σyp [ESE : 1999]

D
Answers Theories of Failure (Static and Dynamic)
1.1 (b) 1.2 (b) 1.3 (b) 1.4 (c) 1.5 (a) 1.6 (d) 1.7 (d) 1.8 (a) 1.9 (c)
A
Explanations Theories of Failure (Static and Dynamic)
1.1 (b) 1.2 (b)

Taking sorderberg criteria the results are more
M
Maximum bending stress σ1 = M

conservative as maximum stress point will be as
Minimum bending stress σ2 = O
shown.
σ1 − σ2 M
Soderberg criterion ∴ Maximum shear stress = =
2 2
Se Goodman criterion Now, according to maximum shear stress theory
Gerber criterion
σper
τmax =
2
σper = M
(σa)
1.3 (b)
Syt Sut Most conservative value means safest design
(σm) i.e largest diameter. For ductile material, maximum
shear stresses of theory gives higher value of
diameter.
Design of Machine Elements 77
1.4 (c) 1.7 (d)

If the diameter or size of the mechanical According to maximum shear theory,
components is more, the surface area is more Sy t 16T
hence greater number of surface defect. Hence, = τ=
2 πd 3
endurance limit of component reduced with
⎛ πd 3 ⎞
increase in size. ∴ Sy t ⎜ ⎟ =T ...(i)
⎝ 32 ⎠
1.5 (a) According to maximum principal stress theory,
The stress concentration effect in ductile material 16T ′
= S yt
Y
for static loading has no serious effect because πd 3
there material undergoes local yielding and πd 3
distribute the stress where maximum value is T ′ = Syt ...(ii)
16
reached.
S
From equation (i) and (ii),
T ′ = 2T
1.6 (d)
A. Maximum principal stress theory 1.8 (a)
A
σ2
IInd Method
Te = M2 +T 2
σ1 For pure torsion M = 0
E
πd3
Te = T = ⋅ τmax
16
B. Maximum shear stress theory and Me = 1 ⎡M + M 2 + T 2 ⎤
σ2 2 ⎢⎣ ⎥⎦
T πd3
E
= = ⋅σ
2 32 max
σ1
τmax
∴ =1:1
σmax
D
C. Maximum octahedral shear stress theory. 1.9 (c)

σ2 MSST σ2
A
σ1 σ1
M
D. Maximum shear strain energy theory

σ2
σ1
2 Bolted, Riveted and
Welded Joint
2.1 The permissible stress in a fillet weld is 2.5 A double fillet welded joint with parallel fillet weld
Y
100 N/mm2. The fillet weld has equal leg lengths of length L and leg B is subjected to a tensile
of 15 mm each. The allowable shearing load on force P . Assuming uniform shear stress
per cm length of the weld is distribution, the shear stress in the weld is given by
(a) 22.5 kN (b) 15.0 kN 2P P
S
(c) 10.6 kN (d) 7.5 kN (a) (b)
BL 2BL
[ESE : 1995]
P 2P
2.2 For bolts of uniform strength, the shank diameter (c) (d) [ESE : 1996]
2 BL BL
A
is made equal to
(a) major diameter of threads 2.6 A butt welded joint, subjected to tensile force P
(b) pitch diameter of threads is shown in the given figure, l = length of the
weld (in mm) h = throat of the butt weld (in mm)
(c) minor diameter of threads
E
(d) nominal diameter of threads and H is the total height of weld including
[ESE : 1995] reinforcement. The average tensile stress σt in the
weld is given by
2.3 Assertion (A): When the coupler of a turn buckle
is turned in one direction both the connecting rods
E
P l
either move closer or move away from each other P
depending upon the direction of rotation of the
h H
coupler.
D
Reason (R): A turn buckle is used to connect P P

two round rods subjected to tensile loading and (a) σt = (b) σt =
Hl hl
requiring subsequent adjustment for tightening P 2P
(c) σt = (d) σt =
or loosening. 2hl hl
A
(a) both A and R are true and R is the correct [ESE : 1997]
explanation of A
2.7 In the welded joint shown in the given figure if the
weld at B has thicker fillets than at A then load
M
explanation of A
carrying capacity P0 of the joint will
[ESE : 1996]
A B
2.4 Two rigid plates are clamped by means of bolt
and nut with an initial force N. After tightening, a
separating force P(P < N) is applied to the lower
plate, which in turn acts on nut. The tension in the
P0
bolt after this is
(a) (N + P) (b) (N – P) (a) increase (b) decrease
(c) P (d) N (c) remain unaffected (d) exactly get doubled
[ESE : 1996] [ESE : 1997]
2.8 When a nut is tightened by placing a washer below 2.12 Which of the following stresses are associated
it the bolt will be subjected to with tightening of nut on a bolt
(a) tensile stress (b) compression stress 1. Tensile stress due to stretching of bolt.
(c) shear stress (d) none of these 2. Bending stress due to bending of bolt.
[ESE : 1998] 3. Crushing and shear stresses in threads.
4. Torsional shear stress due to frictional
2.9 The rivet head used for boiler plate riveting is
resistance between the nut and bolt.
usually
(a) snap head (b) pan head
below:
(c) counter sink head (d) conical head
Y
(a) 1, 2 and 4 (b) 1, 2 and 3
[ESE : 1998]
(c) 2, 3 and 4 (d) 1, 3 and 4
2.10 Two metal plates of thickness ‘t’ and width ‘w’ are [ESE : 1998]
jointed by a fillet weld of 45° as shown in given
S
2.13 For longitudinal joint in boiler, the type of joint used
figure. When subjected to a pulling force ‘F’, the
is
stress induced in the weld will be
(a) lap joint with one ring one slopping the other
45° (b) butt joint with single cover plate
A
F t
(c) butt joint with double cover plate
t F (d) any one of the above [ESE : 1999]
2.14 If permissible stress in plates of joint through a

F F
E
(a) (b) pin as shown in the given figure is 200 MPa, then
wt sin45° wt
the width w will be
F sin45° 2F
(c) (d) Pin
wt wt A
[ESE : 1998] 2000N
E
10 mmφ
w
2.11 The piston rod and the crosshead in a steam 2000N
engine are usually connected by means of 2mm
2mm
(a) Cotter joint (b) Knuckle joint
D
B
(c) Ball joint (d) Universal joint
[ESE : 1998] (a) 15 mm (b) 18 mm
(c) 20 mm (d) 25 mm [ESE : 1999]
A

Answers Bolted, Riveted and Welded Joint
2.1 (c) 2.2 (c) 2.3 (a) 2.4 (d) 2.5 (c) 2.6 (b) 2.7 (c) 2.8 (a) 2.9 (a)
M
2.10 (a) 2.11 (a) 2.12 (d) 2.13 (c) 2.14 (a)
Explanations Bolted, Riveted and Welded Joint
2.1 (c) 2.2 (c)
2p Bolt of uniform strength are made to resist shock

Shear stress is given by τ = load by:
hl
τh 100 × 15
p 1. Making a hole (drilled) i.e., area of shank
⇒ = = reduced to root area.
l 2 2
2. Reducing the diameter of shank of bolt
∴ Load/cm length = 1060 N/mm = 10.6 kN/cm
corresponding to that of minor diameter.
2.4 (d) 2.9 (a)

The correct option is (d) i.e., N The Snap Heads are usually employed for
Initial load = N structural work and machine riveting and for boiler
Separating force = P shell.
Since P < N i.e., separating force is less than The Counter sunk heads are mainly used for
initial load, therefore tension in the bolt will be N. ship building where flush surface are necessary.
If separating force P was larger than N i.e., initial The Conical heads are mainly used in case of
load than the load on the bolt would have been P. hand hammering.
The Pan head have maximum strength, but these
Y
2.5 (c) are difficult to shape.
The correct option is (c) 2.10 (a)
For single fillet The throat h
P = t×L×τ
S
45°
1 t
= hLτ h
2
A
P
L h
t → throat sin45° =
P
t
h = t sin 45°
t
E Area of minimum throat = w × h = wt sin45°
h
F
Shearing force =
wt sin45°
For double fillet
2.11 (a)
⎛ 1 ⎞
P = 2⎜ hLτ⎟ = 2 hLτ The piston rod and the crosshead in steam engine
E
⎝ 2 ⎠
is connected by cotter joint. It is used when no
P
∴ τ = relative motion between the rods is desirable,
2 hL cotters are normally driven at right angle to the
D
2.6 (b) axis of connected part which are subjected to

Because throat area is the minimum area and tensile or compressive stresses.
Athroat = h × L
2.13 (c)
A
P
∴ σt = The longitudinal joint in a boiler shell is usually
hl
butt joint with two cover plates. This joint is more
2.8 (a) efficient than lap joint. It is also stiffer and helps
Bolts are always subjected to tensile stress when
M
to maintain circularity of the shells.

nut is tightened. The washer will be in
compression. 2.14 (a)
It will subjected to single shear as the pin willl be
sheared at the junction of two plates. Permissible
stress given for the plate
2000 = (w – 10) × 2 × 10–6 × 200 × 106
⇒ w = 15 mm

3 Bearings, Shafts, Axles & Keys
(Keys out of syllabus from 2016)
3.1 Consider the following design considerations 3.4 Assertion (A): In equilibrium position, the journal
Y
1. Tensile failure 2. Creep failure inside a journal bearing remains floating on the
3. Bearing failure 4. Shearing failure oil film.
5. Bending failure Reason (R): In a journal bearing, the load on the
The design of the pin of a rocker arm of an I.C. bearing is perpendicular to the axis of the journal.
S
engine is based on (a) both A and R are true and R is the correct
(a) 1, 2 and 4 (b) 1, 3 and 4 explanation of A
(c) 2, 3 and 5 (d) 3, 4 and 5 (b) both A and R are true but R is not a correct
explanation of A
A
[ESE : 1995]
3.2 Which one of the following loadings is considered
for design of axles?
[ESE : 1995]
(a) Bending moment only
E 3.5 In an oil-lubricated journal bearing, coefficient of
(b) Twisting moment only
(c) Combined bending moment and torsion friction between the journal and the bearing
(a) remains constant at all speeds
(d) Combined action of bending moment, twisting
(b) is minimum at zero speed and increases
moment and axial thrust
monotonically with increases in speed
[ESE : 1995]
E
(c) is maximum at zero speed and decreases
3.3 Match List-I with List-II and select the correct monotonically with increase in speed
answer using the codes given below the lists: (d) becomes minimum at an optimum speed and
List-I
D
then increases with further increase in speed

A. Crank shaft [ESE : 1995]
B. Wire shaft
3.6 Removal of metal particles from the raceway of a
C. Axle
rolling contact bearing is a kind of failure of bearing
A
D. Plain shaft known as

List-II (a) pitting (b) wearing
1. Supports the revolving parts and transmits (c) spalling (d) scuffing
torque. [ESE : 1995]
M
2. Transmits motion between shafts where it is

not possible to effect a rigid coupling between
them.
List-I
3. Converts linear motion into rotary motion.
A. High temperature
4. Supports only the revolving parts.
B. High load
Codes: C. No lubrication
A B C D D. Bushings
(a) 3 2 1 4 List-II
(b) 4 2 3 1 1. Teflon bearing
(c) 3 2 4 1 2. Carbon bearing
(d) 1 4 2 3 3. Hydrodynamic bearing
[ESE : 1995] 4. Sleeve bearing
Codes: (a) it is closer to real life situation

A B C D (b) it leads to a safer design
(a) 1 2 3 4 (c) it leads to cost effective design
(b) 4 1 2 3 (d) no other assumption is possible
(c) 2 1 3 4 [ESE : 1996]
(d) 2 3 1 4
3.12 The bearing characteristic number in a
[ESE : 1995]
hydrodynamic bearing depends upon
3.8 Match List-I (Machine element) with List-II (Cause (a) length, width and load
of failure) and select the correct answer using the (b) Length, width and speed
Y
codes given below the lists: (c) Viscosity, speed and load
List-I (d) Viscosity, speed and bearing pressure
A. Axle [ESE : 1996]
B. Cotter
S
3.13 When a shaft transmits power through gears, the
C. Connecting rod
shaft experiences
D. Journal bearing
(a) torsional stresses alone
List-II
A
(b) bending stresses alone
1. Shear stress
(c) constant bending and varying torsional
2. Tensile/compressive stress
stresses
3. Wear
(d) varying bending and constant torsional
4. Bending stress
E stresses [ESE : 1997]
Codes:
A B C D 3.14 Match List-I with List-II and select the correct
(a) 1 4 2 3 answer using the codes given below the lists:
(b) 4 1 2 3 List-I
E
(c) 4 1 3 2 A. Ball bearing
(d) 1 4 3 2 B. Tapered roller bearing
[ESE : 1996] C. Spherical roller bearings
D. Needle roller bearings
D
3.9 A transmission shaft subjected to bending loads List-II

must be designed on the basis of 1. Heavy loads with oscillatory motion
(a) maximum normal stress theory 2. Light loads
A
(b) maximum shear stress theory 3. Carrying both radial and thrust loads
(c) maximum normal stress and maximum shear 4. Self-aligning property
stress theories
(d) fatigue strength Codes:
M
[ESE : 1996] A B C D
(a) 4 1 3 2
3.10 Tapered roller bearings can take (b) 2 1 4 3
(a) radial load only (c) 2 3 1 4
(b) axial load only (d) 2 3 4 1
(c) both radial and axial load and the ratio of these [ESE : 1997]
being less than unity
(d) both radial and axial load and the ratio of these 3.15 In a journal bearings, the radius of the friction
being greater than unity circle increases with the increase in
[ESE : 1996] (a) load
(b) radius of the journal
3.11 The bearing characteristic number in a (c) speed of the journal
hydrodynamic bearing depends on (d) viscosity of the lubricant [ESE : 1997]
3.16 Which one of the following statements is NOT true Codes:

of rolling contact bearing? A B C D
(a) The bearing characteristic number is given (a) 1 4 2 3
by ZN/p where Z is the absolute viscosity of (b) 4 1 2 3
the lubricant, N is the shaft speed and p is (c) 4 1 3 2
the bearing pressure. (d) 1 4 3 2
(b) Inner race of a radial ball bearing has an [ESE : 1998]
interference fit with the shaft and rotates along
3.19 Consider the following statements.
with it.
A splined shaft is used for
Y
(c) Outer race of the bearing has an interference
1. Transmitting power
fit with bearing housing and does not rotate.
2. Holding a flywheel rigidly in position
(d) In some cases, the inner race is stationary
3. Moving axially the gear wheels mounted on
and outer race rotates.
S
it
[ESE : 1997]
4. Mounting V-belt pulleys on it
3.17 Match L i s t - I (Type of keys) with L i s t - I I Which of these statements are correct?
(Characteristic) and select the correct answer (a) 2 and 3 (b) 1 and 4
A
using the codes given below the lists: (c) 2 and 4 (d) 1 and 3
List-I [ESE : 1998]
A. Woodruff key
3.20 In the assembly design of shaft, pulley and key,
B. Kennedy key
E
C. Feather key the weakest member is
D. Flat key (a) Pulley (b) Key
List-II (c) Shaft (d) None
1. Loose fitting, light duty [ESE : 1998]
E
2. Heavy duty
3.21 Assertion (A): Hydrostatic lubrication is more
3. Self aligning
advantageous when compared to hydrodynamic
4. Normal industrial use
lubrication during starting and stopping the journal
Codes:
D
in its bearing.
A B C D
Reason (R): In hydrodynamic lubrication, the fluid
(a) 2 3 1 4
film pressure is generated by the rotation of the
(b) 3 2 1 4
journal.
A
(c) 2 3 4 1
(d) 3 2 4 1 [ESE : 1997]
explanation of A
3.18 Match List-I (Machine element) with List-II (Cause (b) both A and R are true but R is not a correct
M
of failure) and select the correct answer using the explanation of A

codes given below the lists: (c) A is true but R is false
List-I (d) A is false but R is true
A. Axle [ESE : 1998]
B. Cotter
C. Connecting rod 3.22 Match List-I with List-II and select the correct
D. Journal bearing answer using the codes given below the lists:
List-II List-I
1. Shear stress A. End thrust
2. Tensile/compressive stress B. No cage
3. Wear C. More accurate centering
4. Bending stress D. Can be overloaded
List-II 3.24 In a single row deep groove ball bearing, cages

1. Plain bearing are needed to
2. Ball bearing (a) separate the two races
3. Needle bearing (b) separate the balls from inner race
4. Tapered roller bearing (c) separate the outer race from the ball
Codes: (d) ensure that the balls do not cluster at one
A B C D point and maintain proper relative angular
(a) 3 4 2 1 portion
(b) 4 3 1 2 [ESE : 1999]
Y
(c) 3 4 1 2
3.25 Which one of the following types of bearings is
(d) 4 3 2 1 [ESE : 1998]
employed in shafts of gear boxes of automobiles?
3.23 The shearing area of a key of length ‘l’ breadth ‘b’ (a) Hydrodynamic journal bearings
depth ‘h’ is equal to
S
(b) Multi lobed journal bearings
(a) b × h (b) L × h
(c) Antifriction bearings
h
(c) L × b (d) L × [ESE : 1998] (d) Hybrid journal bearings [ESE : 1999]
2
A

Answers Bearings, Shafts, Axles and Keys
3.1 (d) 3.2 (a) 3.3 (c) 3.4 (b) 3.5 (d) 3.6 (a) 3.7 (d) 3.8 (b)
3.9 (c) 3.10 (d) 3.11 (a)
E 3.12 (d) 3.13 (a) 3.14 (d) 3.15 (b) 3.16 (a)
3.17 (b) 3.18 (b) 3.19 (d) 3.20 (b) 3.21 (a) 3.22 (d) 3.23 (c) 3.24 (d)
3.25 (c)
Explanations Bearings, Shafts, Axles and Keys

E
3.1 (d) Plain shaft supports the revolving parts and

Force = Gas force + Inertia force. transmits torque.
This force resisted by bearing pressure between
D
3.4 (b)
the piston pin and the support length.
Journal is in floating condition with balanced force
Since the force is u.d.l. so bending moment the
created by hydrodynamic pressure.
pin fail is double shear near bosses ovalization
The load is perpendicular to the axis.
A
is done to (elliptical shape) to take account of w

non linear distribution of forces. The pin should L
ns
be checked for induced shear. Rocker arm is
generally of I-section, but for low speed engines it
M
d
can be rectangular section. Due to load on the
valve, rocker arm is subjected to bending moment.
3.5 (d)
3.2 (a) Mixed Hydrodynamic
Boundary
lubrication lubrication lubrication
Axle supports rotating member therefore bending
stresses but not rotates itself.
Coefficient of friction
3.3 (c)
Wire shaft is also called Flexible shaft and it
transmit motion between shaft where it is not
possible to effect a rigid coupling between them.
(ZN/P)
Axle supports only revolving parts.
Bearing characteristic number
3.6 (a) 3.10 (d)
1. Pitting is a surface fatigue failure that occurs Fr

> 1 because majority of load carried is radial
when load on the bearing exceeds the surface Fa
endurance strength. This is frequently found and some part axial.
in ball bearing. 3.12 (d)
2. Wearing occurs when surfaces slide against Bearing characterstic No.
each other and there is insufficient or no ⎡ 3n D L ⎤
lubrication to keep them apart. μ ∝F ⎢ × × ⎥
⎣ p c D⎦
Y
3. Spalling: when a progressive failure pitting zn
or = bearing characterstic no.
reaches a certain stage, the metal between p
adjacent pits tends to be weakended and where = z = viscosity; n = speed
S
eventually breaks of this effect is known as p = bearing pressure
spalling.
3.13 (a)
4. Scuffing is a complex phenomenon of severe
P = T×ω
A
adhesive wear generated under particular
π
combinations including contact pressure, ∴ T= × τ × d3
16
lubrication, speed and friction. Scuffing
∴ Torque depends on torsional stress only.
E
involves the sudden collapse of the lubricant
film and is generally regarded as resulting from 3.14 (d)
thermal phenomena. Ball bearing - Light loads.
Tapered roller bearing - Carrying both radial and
3.7 (d)
thrust load.
E
Teflon Bearing : No external lubricant like oil Spherical roller bearing - Self aligning bearing
Carbon Bearing : High temperature application Needle roller bearing - Heavy load with oscillatory
Hydrodynamic : High load motion.
D
Bearing
Sleeve Bearing : Bushing 3.15 (b)
x = μR
3.8 (b)
A
Axle supports rotating member but itself it never 3.16 (a)

rotates. So torque is absent. First statements is not valid for rolling contact
∴ Therefore designed only for bending stress. bearing.
M
Connecting rod takes tensile and compressive 3.17 (b)

force arising from piston moment.
Wear is the criteria for Journal bearing. W oodr uf
ufff Key: It is a sunk key, in the form of an
oodruf
almost semiconductor disk of uniform thickness.
3.9 (c) Once placed in position, the woodruff key tilts
and aligns itself on the shaft.
Transmission shafts which is subjected to only
bending stress are known as Axle. For pure Kennedy Key: It consists of two square keys
bending case both theories will give same and it is used for heavy duty applications.
results. Feather Key: It is used for light duty.
Flat Key: Normal industrial use.
3.18 (b) 3.22 (d)

Axle supports rotating member but itself it never End thrust – Tapered roller bearing
rotates. So torque is absent. No cage – Needle bearing
∴ Therefore designed only for bending stress. More accurate centering – Ball bearing
Connecting rod takes tensile and compressive
Can be overloaded – Plain bearing.
force arising from piston moment.
Wear is the criteria for Journal bearing. 3.23 (c)
3.19 (d) Shearing area = L × b

Where, L is length of key, and b is width of key.
Y
Splines are used when there is requirement of
relative axial motion between shaft and hub. The
3.24 (d)
gear shifting mechanism in automobile uses this
mechanism. In a single row deep grove ball bearing, cages
S
are needed to ensure that the balls do not cluster
3.20 (b) at one point and maintain proper relative angular
Key should be weakest member as it should fail portion.
first to give notice that torque has exceeded
A
hence to save the shaft and mechanical elements 3.25 (c)
mounted on it. Rolling contact bearings are also called anti
3.21 (a) friction bearing or simply ball bearing. It is
E employed in shaft of gear boxes of automobiles.
The correct option is (a) i.e., both A and R are

true and R is the correct explanation of (a)’ A.
Since in hydrodynamic lubrication the fluid
pressure is generated by the rotation of journal
therefore at starting and stopping of journal
E
bearing their will be a metal to metal contact since

their is no sufficient pressure therefore in this case
hydrostatic lubrication is more advantageous.
D
A
M
4 Gears
4.1 The design of gear on account of Spott’s equation (a) 1 alone (b) 2, 3 and 4
Y
which account for dynamic load is based on (c) 1, 2, and 3 (d) 1, 2, 3 and 4
(a) contact stress based on Hertz theory [ESE : 1998]
(b) allowable stress based on maximum shear
4.3 Assertion (A): Shafts supporting helical gears
stress theory
must have only deep groove ball-bearings.
S
(c) distortion energy theory
Reason (R): Helical gears produce axial thrusts.
(d) Octahedral stress theory [ESE : 1998]
4.2 Consider the following characteristics: explanation of A
A
1. Small interference (b) both A and R are true but R is not a correct
2. Strong tooth explanation of A
3. Low production cost (c) A is true but R is false
4. Gear with small number teeth (d) A is false but R is true [ESE : 1999]
E
Those characteristics which are applicable to Stub

20° involute system would include
Answers Gears
4.1 (a) 4.2 (d) 4.3 (a)

E
Explanations Gears
4.1 (a) 4.3 (a)

D
It is based on contact stress based on Hertz Helical gears has three force component Ft, Fr,
theory. It arises when-there is point contact and Fa (Tangential, radial and axial) so deep groove
dynamic load is acting. ball bearing must be used as it can take radial
A
and thrust force simultaneously.

4.2 (d)

20° stub tooth involute: Stub mean 20% less
working depth than full depth gear so addendum
M
is shorter (small interference is stub system. (The

tooth becomes stronger as the lever arm of
bending moment on tooth is reduced. Machining
cost is less as compared to full depth system as
less metal must be cut away minimum no of teeth
on pinion to avoid interference is 14.
5 Brakes, Clutches and Ropes
(Ropes out of Syllabus)
5.1 Effective stress in wire ropes during-normal (a) 11 (b) 12
Y
working is equal to the stress due to (c) 10 (d) 22 [ESE : 1997]
(a) axial load plus stress due to bending
5.4 On the motors with low starting torque, the type
(b) acceleration/retardation of masses plus
of the clutch to be used is
stress due to bending
S
(a) multiple-plate clutch
(c) axial load plus stress due to acceleration/
(b) cone clutch
retardation
(c) centrifugal clutch
(d) bending plus stress due to acceleration/
(d) single-plate clutch with both sides effective
A
retardation [ESE : 1996]
[ESE : 1999]
5.2 Given that W = Weight of load handled,
5.5 Assertion (A): In case of friction clutches, uniform
Wr = Weight of rope and f = Acceleration, the
wear theory should be considered for power
E
additional load in ropes of a hoist during starting transmission calculation rather than the uniform
is given by pressure theory.
⎛ W − Wr ⎞ ⎛ W + Wr ⎞ Reason (R): The uniform pressure theory gives
(a) Fa = ⎜ f (b) Fa = ⎜ f
⎝ g ⎟⎠ ⎝ g ⎟⎠ a higher friction torque than the uniform wear
W theory.
Wr
(c) Fa = f
E
(d) Fa = f (a) both A and R are true and R is the correct
g g explanation of A
[ESE : 1997]
5.3 In a multiple disc dutch, if there are 6 discs on the explanation of A
D
driving shaft and 5 discs on driven shaft, the number (c) A is true but R is false
of pairs of contact surfaces will be equal to (d) A is false but R is true [ESE : 1999]

A
Answers Brakes, Clutches and Ropes

5.1 (a) 5.2 (b) 5.3 (c) 5.4 (c) 5.5 (b)
Explanations Brakes, Clutches and Ropes

M
5.1 (a) 5.4 (c)

Because during normal operation acceleration Low starting torque permits the shoes to stick
avoided. So direct stress and bending stress before running to full speed.
accounted. All the other clutches mentioned are for high torque.
5.2 (b) 5.5 (b)

⎛ mass of rope + mass of weight⎞ Uniform pressure theory is applicable only when
n
⎜⎝ to be raised be raised ⎟⎠ × accl the clutches are new i.e., the assumption involved
is that axial force W is uniformly distributed.
= inertia force acting as additional load
Moreover torque transmitted in uniform pressure
5.3 (c) is more hence for safety in design uniform wear
n1 = 6, n2 = 5 theory is used.
N = n1 + n2 –1 = 6 + 5 – 1 = 10
6 Power Screws
(Out of Current Syllabus)
6.1 While designing a screw in a screw jack against
Y
buckling failure, the end conditions for the screw
are taken as P
(a) both the ends fixed

(b) both the ends hinged
S
(c) one end fixed and other end hinged h
(d) one end fixed and the other end free
[ESE : 1995]
A
6.2 The load cup of a screw jack is made separate
from the head of the spindle to
(a) enhance the load carrying capacity of the jack dr
E
(b) reduce the effort needed for lifting the working d
load
2F F
(c) reduce the value of frictional torque to be (a) πd h (b) πd h
r r
countered for lifting the load
(d) prevent the rotation of load being lifted 2F F
E
[ESE : 1995] (c) (d)
πdh πdh
6.3 To ensure self-locking in a screw jack it is essential [ESE : 1997]
that helix angle is
D
6.6. The maximum efficiency of self locking screw is

(a) larger than friction angle
(a) 50% (b) 70%
(b) smaller than friction angle
(c) 75% (d) 80%
(c) equal to friction angle
[ESE : 1997]
A
(d) such as to give maximum efficiency in lifting

[ESE : 1996] 6.7 The diameter of tommy bar for a screw jack is
designed for
6.4 The friction torque for square thread at mean
(a) bending moment due to effort applied
M
radius while raising load is given by

(w = load, R0= mean radius, φ = angle of friction, (b) torque on the tommy bar due to effort applied
α = lead angle) (c) a percentage of axial loads
(a) wR0tan(φ – α) (b) wR0tan (φ + α) (d) some axial loads coupled with transverse
(c) wR0tanα (d) wR0tanφ loads
[ESE : 1997] [ESE : 1999]
6.5 Consider the case of square threaded screw 6.8 Which of the following screw thread is adopted
loaded by a nut as shown in the given figure. The for power transmission in either direction?
value of the average shearing stress of the screw (a) Acme thread (b) Square thread
is given by (symbols have the usual meaning) (c) Buttress thread (d) Multiple thread
[ESE : 1999]

Answers Power Screws

6.1 (d) 6.2 (d) 6.3 (b) 6.4 (b) 6.5 (c) 6.6 (a) 6.7 (a) 6.8 (a)
Explanations Power Screws

6.1 (d) P
t =
One end fixed and other end free. as lower part 2
of screw is free to rotate. The screw acts as F 2F 2F
= =
column. τ = πd Z P πdr ZP πdr h
Y
r
2
6.2 (d) 2F
i.e., τ = πd h
There is provision to prevent rotation by making r
S
load cup separate from the head of the spindle.
6.6 (a)
6.3 (b) η of screw
φ > α [i.e. Friction Angle > Helix Angle]
A
tan φ ≥ tan α tan φ
∴ η=
tan(α + φ)
np
tan φ ≥
πd m ∴ for self locking φ ≥ α or α ≤ φ
E
tan φ 1 tan2 φ
6.4 (b) η≤ or −
tan(φ + φ) 2 2
Torque required to raise the load
T1 = WR tan(φ + α). ∴ From this expression η of self locking screw
is less than ½ or 50% if the η is more then
E
Torque required to lower load
T2 = WR tan(φ – α). 50% screw is said to be overhauling.
So maximum η is 50%
6.5 (c)
D
The correct option is (c) 6.7 (a)

The diameter of tommy bar of screw jack is
F
Shea stress τ = designed for bending moment due to effort
πdr Zt
A
applied at its end.

Where Z is the no. of threads in engagement with
6.8 (a)
the nut
t = thread thickness at the core diameter Acme thread is used for power transmission in
M
also height of the nut h = ZP either direction.

where P is the pitch of the thread for square thread
7 Helical Springs
7.1 In the calculation of induced shear stress in the (b) direct shear stress only
Y
helical springs, the wahl correction factor is used (c) a combination of torsional shear stress and
to take of bending stress
(a) combined effect of transverse shear stress (d) a combination of bending stress and direct
and bending stress is wire shear stress
S
(b) combined effect of bending stress and [ESE : 1996]
curvature of wire 7.5 A long helical spring having a spring stiffness of
(c) combined effect of transverse shear stress 12 kN/m and number of turns 20, breaks into two
A
and curvature of wire parts then stiffness of the resultant spring will be
(d) combined effect of torsional shear stress & (a) 6 kN/m (b) 12 kN/m
transverse shear stress of wire (c) 24 kN/m (d) 30 kN/m
[ESE : 1995] [ESE : 1996]
E
7.2 A closely coiled helical spring is acted upon by 7.6 Wahl stress factor takes into account
axial force. The maximum shear stress developed (a) direct shear stress
in the spring is τ. Half of the length of spring is (b) torsional shear stress
cut off and the remaining spring is acted upon by (c) wire curvature effect
E
the same axial force. The maximum shear stress (d) direct shear and wire curvature effect
in the spring the new condition will be [ESE : 1997]
(a) 1/2 τ (b) τ
7.7 Two closed coil springs are made from the same
D
(c) 2τ (d) 4τ
small diameter wire, one wound on 2.5 cm
[ESE : 1995] diameter core and the other on 1.25 cm diameter
7.3 Given that core. If each spring had ‘n’ coils, then the ratio of
A
d = diameter of spring their spring constants would be

R = mean radius of coils (a) 1/16 (b) 1/8
n = number of coils and (c) 1/4 (d) 1/2
G = modulus of rigidity [ESE : 1998]
M
The stiffness of the close-coiled helical spring 7.8 A closed-coil helical spring is subjected to a
subject to an axial load W is equal to moment about its axis. The spring wire would
Gd 4 Gd 3 experience a
(a) (b) (a) bending stress
64R 3n 64R 3n
(b) direct tensile stress of uniform intensity at its
Gd 4 Gd 4
(c) (d) cross-section
32R 3n 64R 2n
(c) direct shear stress
[ESE : 1996]
(d) torsional shearing stress [ESE : 1998]
7.4 When a close coiled helical spring is subjected
7.9 A helical spring has N turns of coil of diameter D,
to a couple about its axis, the stress induced in
and a second spring, made of same wire diameter
the wire material of the spring is
and a same material, has N/2 turns of coil of
(a) bending stress only
diameter 2D. If the stiffness of the first spring (c) innermost fibres
is k, then the stiffness of the second spring will be (d) end coils [ESE : 1999]
(a) k/4 (b) k/2
7.11 If a compression coil spring is cut into two equal
(c) 2k (d) 4k [ESE : 1999]
parts and the parts are then used in parallel, the
7.10 The maximum shear stress occurs on the ratio of the spring rate to its initial value will be
outermost fibres of a circular shaft under torsion. (a) 1
In a close-coiled helical spring the maximum (b) 2
shear stress occurs on the (c) 4
(a) outermost fibres (d) Indeterminable for want of sufficient data
Y
(b) fibres at mean diameter [ESE : 1999]

Answers Helical Springs
S
7.1 (c) 7.2 (b) 7.3 (a) 7.4 (a) 7.5 (c) 7.6 (d) 7.7 (b) 7.8 (a) 7.9 (a)
7.10 (c) 7.11 (c)
A
Explanations Helical Springs
7.1 (c) δ =R ×θ
Resultant shear stress in wire where δ = Deflection of spring
E
8WD 4W TL
τ = τ1 + τ2 = + θC = angle of twist =
πd πd 2 3
GJ
Maximum shear stress in wire
TL
= Torsional shear stress + Direct shear stress ∴ δ=R × ...(i)
GJ
E
8WD 4W 8WD ⎛ d ⎞ Now T = W × R
= + = ⎜1 + ⎟
πd 3 πd 2 πd 3 ⎝ 2D ⎠ L = 2π Rn
4c − 1 0.615 π 4
τ = k × 8WD ,k = + J=d
πd
3 4c − 4
D
c 32
{to consider the effect of both direct shear as From equation ...(i)
well as curvature of the wire} W × R × 2πR × n 64WR 3n
or k = ks × kc δ=R× =
π 4 Gd 4
G×
A
ks = direct shear stress correction factor d

32
kc = correction factor for curvature effect Spring constant or stiffness factor is defined as
the axial force required to produce unit deflection.
7.2 (b)
M
W
∴ spring constant (k) =
⎛ 8WD ⎞ δ
Shear stress in helical spring = ks ⎜ where
⎝ πd 3 ⎟⎠ Gd 4
∴ k=
64R 3n
⎛ 0.5 ⎞
ks = shear stress correction factor = ⎜ 1 +
⎝ C ⎟⎠ 7.4 (a)
Hence shear stress is independent of the length
When twist is applied to closed helical spring,
of spring.
then only bending stresses are induced
7.3 (a)
7.5 (c)
The deflection of a close coil helical spring
subjected to axial force ‘W’ is Gd 4
k=
64R 3n
1 k2 n1 k2 20 k1 1
k∝ ⇒ = ∴ = ∴ =
n k1 n2 12 10 k2 8
∴ k2 = 24 kN/m
7.8 (a)
7.6 (d)
When a closed coil helical spring, fixed at one
Since the spring rod is bent into a curve, the shear end is subjected at the other end to a twisting
stress on the inner surface is more than the shear couple about the central axis of the spring,
stress developed on the outer surface. To take bending moment will be produced at all the cross-
into account the curvature effect. Wahl’s sections.
Y
correction factor may be applied and maximum
shear stress can be calculated as follows. 7.9 (a)
⎛ 16WR ⎞ Gd 4
τmax = KW ⎜⎝ ⎟ Stiffness; k =
S
πd 3 ⎠ 8D 3N
where KW is Wahl’s correction factor and is given Gd 4 k
Now k′ = =
by N 4
8(2D )3 ×
A
2
⎛ 4c − 1 0.615 ⎞
KW = ⎜⎝ +
4c − 4 c ⎟⎠ 7.11 (c)
where ‘c’ is the spring index When a spring is cut into two number of coils
E So stiffness of each spring becomes doubled
7.7 (b) when type are connected in parallel.
Gd 4
Spring constant : k = stiffness = 2k + 2k = 4k
8D 3n
1
∴ k∝
D3
E
k1 × (2.5)3 = k2 × (1.25)3
D
A
M
8 Miscellaneous
(Out of Syllabus from 2016)
8.1 Sources of power loss in a chain drive are given 8.4 In flat belt drive, if the slip between the driver
Y
below: and the belt is 1%, that between belt and follower
1. Friction between chain and sprocket teeth. is 3% and driver and follower pulley diameters
2. Overcoming the chain stiffness. are equal, then the velocity ratio of the drive will
3. Overcoming the friction in shaft bearing. be
S
4. Frictional resistance to the motion of the chain
(a) 0.99 (b) 0.98
in air or lubricant.
(c) 0.97 (d) 0.96
To correct sequence of descending order of power
[ESE : 1996]
loss due to these sources is
A
(a) 1, 2, 3, 4 (b) 1, 2, 4, 3 8.5 When belt drive is transmitting maximum power
(c) 2, 1, 3, 4 (d) 2, 1, 4, 3 (a) effective tension is equal to centrifugal tension
[ESE : 1995] (b) effective tension is half of centrifugal tension
E
8.2 Match List-I (Different type of detachable joints) (c) driving tension on slack side is equal to the
with List-II (Specific use of detachable Joints) and centrifugal tension
select the correct answer using the codes given (d) driving tension on tight side is twice the
below the lists:
centrifugal tension
List-I
[ESE : 1996]
E
A. Cotter joint
B. Knuckle joint 8.6 Assertion (A): It is desirable to increase the
C. Suspension Link joint length of arc over which the oil film has to be
D. Turn buckle (adjustable joint) maintained in a journal bearing.
D
List-II Reason (R): The oil pressure becomes negative

1. Tie rod of wall crane
in the divergent part and the partial vacuum
2. Suspension bridge
created will cause air to leak in from the ends of
3. Diagonal stays in boiler
A
bearing.
4. Cross head of a steam engine
Codes:
M
(a) 4 2 3 1
(b) 4 3 2 1 explanation of A
(c) 3 2 1 4 (c) A is true but R is false
(d) 2 1 4 3 [ESE : 1995] (d) A is false but R is true
8.3 The power transmitted by a belt is dependent on [ESE : 1996]
the centrifugal effect in the belt. The maximum
8.7 If μ is the actual coefficient of friction in a belt
power can be transmitted when the centrifugal
moving in a grooved pulley, the groove angle
tension is
(a) 1/3 of tension (T1) on the tight side being 2α , the virtual coefficient of friction will
(b) 1/3 of total tension (Tt) on the tight side (a) μ/sin α (b) μ/cos α
(c) 1/3 of the tension (T2) on the slack side (c) μsin α (d) μcos α
(d) 1/3 of sum of tension T 1 and T 2 i.e., [ESE : 1997]
1/3(T1 + T2) [ESE : 1996]
8.8 In the case of a vertical belt pulley drive with TC (c) 1, 2 and 3 (d) 1, 2 and 4
as centrifugal tension and T0 as the initial tension, [ESE : 1998]
the belt would tend to hang clear of the lower pulley
8.12 Centrifugal tension in belts is
when
(a) useful because it maintains some tension
(a) TC < T0 (b) TC = T0/3
even when no power is transmitted
(c) TC > T0 (d) TC = T0/2
(b) not harmful because it does not take part in
[ESE : 1997]
power transmission
8.9 Given that T1 and T2 are the tensions on the tight (c) harmful because it increases belt tension and
and slack of the belt respectively, the initial reduces the power transmitted
Y
tension of the belt taking centrifugal tension TC is (d) a hypothetical phenomenon and does not
equal to actually exist in belts [ESE : 1999]
T1 + T2 + TC T1 + T2 + 2TC
(a) (b) 8.13 Match List-I (Different types of detachable joints)
S
3 2
List-II (Specific use of these detachable joints)
T1 + T2 + 3TC T1 + T2 + 4TC
(c) (d) and select the correct answer using the codes
3 4 given below the lists:
[ESE : 1997]
A
List-I
8.10 When the shafts are neither parallel nor A. Cotter joint
intersecting, power can be transmitted by using B. Knuckle joint
(a) a pair of spur gears C. Suspension link joint
(b) a pair of helical gears
E D. Turn buckle (adjustable joint)
(c) an oldham coupling List-II
(d) a pair of spiral gears [ESE : 1998] 1. Tie rod of a wall crane
8.11 Which of the following stresses are associated 2. Suspension bridges
3. Diagonal stays in boiler
E
with design of pins in bushed pin-type flexible
coupling? 4. Cross-head of a steam engine
1. Bearing stress Codes:
2. Bending stress A B C D
D
3. Axial tensile stress (a) 4 2 3 1

4. Transverse shear stress (b) 4 3 2 1
(c) 3 2 1 4
(a) 1, 3 and 4 (b) 2, 3 and 4
(d) 2 1 4 3 [ESE : 1999]
A

Answers Miscellaneous
8.1 (a) 8.2 (a) 8.3 (b) 8.4 (d) 8.5 (d) 8.6 (a) 8.7 (a) 8.8 (c) 8.9 (b)
M
8.10 (d) 8.11 (d) 8.12 (c) 8.13 (a)
Explanations Miscellaneous
8.1 (a) force or axial compressive force application-

joint between the piston rod and the cross-
This is the decreasing order in which losses takes
head of steam engine.
place.
B. Knuckle joint is used to connect two rods
8.2 (a) whose axes either coincide or intersect and
A. Cotter joint is used to connect two co-axial lie in one plane.
rods, which are subjected to either axial tensile Application joint between the links of
suspension bridge.
C. Suspension link joint diagonal stays in boiler. 8.7 (a)

D. Turn buckle (adjustable joint) Limiting tension ratio of the v-belt is
Application Tie rod of wall crane. ⎛ μ ⎞
T1 .θ
⎝⎜ sin α ⎠⎟
e
8.3 (b) T2 =
P = (F1 – F2)v μ
where μ′ = μ called effective coefficient of
sin α
⎛ 1 ⎞
P = F1 ⎜ 1 −
⎝ F1 / F2 ⎟⎠
( )
v = F1 1 − e −μθ v friction
8.9 (b)
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(
P = (Ft1 − Fc )v 1 − e −μθ ) Ft1 = Fi + Fi − Ft2
dP
=0 (∵ Fe = mv2) 2Fi = Ft1 + Ft2
dV
S
Ft1 − 3mV 2 = 0 F1 + F2 + 2Fc T + T + 2Tc
Fi = == 1 2
Ft1 = 3Fc 2 2
A
Ft1 8.10 (d)
Fc =
3 Spiral gears — Non-parallel and non intersecting.
1
of total tension on tight side.
3
E 8.11 (d)
Stresses associated with design of bushed pin-
8.4 (d) type flexible coupling.
N2 d1 ⎡ S1 S2 ⎤ 1. Bearing stress
= ⎢1 − 100 − 100 ⎥
N1 d 2 ⎣ ⎦ 2. Bending stress
E
V2 S S 3. Compressive stress
⇒ = 1− 1 − 2 4. Transverse shear stress
V1 100 100
V2
D
1 3 8.12 (c)
⇒ = 1− − = 0.96
V1 100 100 Increase in centrifugal force is harmful as belt
tries to come out of the pulley and it also reduces
8.5 (d)
the power transmission.
A
Ft1 F1 + Fc
Fc = = ⇒ 3Fc = F1 + Fc 8.13 (a)
3 3
Cotter joint - cross head of steam engine
2Fc = F1
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Knuckle joint - Diagonal stays of boiler

8.6 (a) Suspension joint - Suspension bridge
Side leak (axial) in nature and is constantly Turn buckle - Tie rod of a wall crane.
leaking through the end of bearing as the journal
speeds up.
UNIT
Y
Manufacturing Engineering
S
Syllabus
A
Metal casting-Metal forming, Metal Joining, Machining and machine tool operations, Limits, fits and tolerances,
Metrology and inspection, computer Integrated manufacturing and FMS.
E
E
Contents
D

A
1. Metal Casting ..................................................................................................................... 98
2. Metal Forming and Sheet Metal Operations ..................................................................... 101

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3. Joining/Welding ............................................................................................................... 104
4. Machining and Machine Tool Operation ........................................................................... 106
5. Metrology and Inspection ................................................................................................ 123
6. NC, CNC, DNC, APT, Automation ..................................................................................... 124
7. Non-conventional Machining Process ............................................................................... 127
8. Powder Metallurgy ........................................................................................................... 128

1 Metal Casting
1.1 Assertion (A): Aluminium alloys are cast in hot 1. Dry silica sand
Y
chamber die casting machine. 2. Clay
Reason (R): Aluminium alloys require high 3. Phenol formaldehyde
melting when compared to zinc alloys. 4. Sodium silicate
(a) both A and R are true and R is the correct Those used for shell mould casting include
S
explanation of A (a) 1, 2 and 4 (b) 2, 3 and 4
(b) both A and R are true but R is not a correct (c) 1 and 3 (d) 1, 2, 3, and 4
explanation of A [ESE : 1996]
A
1.5 Which of the following methods are used for
(d) A is false but R is true [ESE : 1995] obtaining directional solidification for riser design?
1.2 Match List-I (Product) with List-II (Process of 1. Suitable placement of chills.
Manufacture) and select the correct answer using 2. Suitable placement of chaplets.
E 3. Employing padding.
the codes given below the lists:
List-I Which of these statements are correct?
A. Automobile piston in aluminium alloy (a) 1 and 2 (b) 1 and 3
B. Engine crankshaft in spheroidal graphite iron (c) 2 and 3 (d) 1, 2, and 3
[ESE : 1996]
C. Carburettor housing in aluminium alloy
E
D. Cast titanium blades 1.6 Misrun is a casting defect which occurs due to
List-II (a) very high pouring temperature of the metal.
1. Pressure die-casting (b) insufficient fluidity of the molten metal.
D
2. Gravity die-casting (c) absorption of gases by the liquid metal.

3. Sand casting (d) improper alignment of the mould flasks.
4. Precision investment casting [ESE : 1996]
5. Shell moulding.
A
1.7 Which of the following pairs are correctly matched?

Codes:
1. Pit moulding ...For large jobs
A B C D
2. Investment moulding ...Lost wax process
(a) 2 3 1 5
3. Plaster moulding ...Mould prepared in
M
(b) 3 2 1 5
gypsum
(c) 2 1 3 4
(a) 1, 2, and 3 (b) 1 and 2
(d) 4 1 2 3
(c) 1 and 3 (d) 2 and 3
[ESE : 1995]
[ESE : 1996]
1.3 Directional solidification in castings can be 1.8 Which one of the following pairs is not correctly
improved by using matched?
(a) chills and chaplets (a) Aluminium alloy piston ...Pressure die casting
(b) chills and padding (b) Jewellery ... Lost wax process
(c) chaplets and padding (c) Large pipes ... Centrifugal casting
(d) chills, chaplets and padding [ESE : 1995] (d) Large bells ... Loam moulding
1.4 Consider the following ingredients used in [ESE : 1997]
moulding
Manufacturing Engineering 99
1.9 If the melting ratio of a cupola is 10 : 1, then the (a) Sprue and riser (b) Ingate and riser
coke requirement for one ton melt will be (c) Drag and runner (d) Riser and runner
(a) 0.1 ton (b) 10 tons [ESE : 1998]
(c) 1 ton (d) 11 tons [ESE : 1997]
1.13 Which of the following are the requirements of an
1.10 Assertion (A): Steel can be melted in hot blast ideal gating system?
cupola. 1. The molten metal should enter the mould
Reason (R): In hot blast cupola, the flue gases cavity with as high a velocity as possible.
are used to preheat the air blast to the cupola so 2. It should facilitate complete filling of the
that the temperature in the furnace is considerably mould cavity.
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higher than that in a conventional cupola. 3. It should be able to prevent the absorption of
(a) both A and R are true and R is the correct air or gases from the surroundings on the
explanation of A molten metal while flowing through it.
S
explanation of A below:
(c) A is true but R is false (a) 1, 2 and 3 (b) 1 and 2
(d) A is false but R is true [ESE : 1997] (c) 2 and 3 (b) 1 and 3 [ESE : 1998]
A
1.11 Which one of the following refractory materials is 1.14 A spherical drop of molten metal of radius 2mm
recommended for steel furnaces containing CaO was found to solidify in 10 seconds. A similar
slag? drop of radius 4mm would solidify in
(a) Alumina (b) Silica
E (a) 14.14 second (b) 20 seconds
(c) Magnesia (d) Fireclay [ESE : 1997] (c) 18.30 second (d) 40 seconds
[ESE : 1998]
1.12 A sand casting mould assembly is shown in the
given figure. The elements marked A and B are 1.15 In solidification of metal during casting,
compensation for solid contraction is
E
respectively
A B (a) Provided by the oversize pattern
(b) Achieved by properly placed risers
(c) Obtained by promoting direction solidification
D
(d) Made by providing chills [ESE : 1999]

A
Answers Metal Casting

M
1.1 (d) 1.2 (a) 1.3 (b) 1.4 (c) 1.5 (b) 1.6 (b) 1.7 (a) 1.8 (a) 1.9 (a)
1.10 (a) 1.11 (b) 1.12 (a) 1.13 (c) 1.14 (d) 1.15 (a)
Explanations Metal Casting

1.1 (d) 1.3 (b)
Due to sticking tendency of Al life of goosneck Chills and padding can be used to improve
is reduced. It is not used in hot chamber die directional solidification.
casting. Material are used and aluminium alloy
having high melting point. The melting point of 1.4 (c)
Aluminium and zinc are 660°C and 422°C In shell moulding, dry silica sand and phenol
respectively. formaldehyde used.
1.5 (b) 1.13 (c)

Chills and padding are use to increase the rate Main requirements of an ideal gating system is
of cooling. Chaplet are anchors of core. it should facilitate complete filling of the mould
cavity and should be able to prevent the
1.6 (b) absorption of air or gases from the surroundings
Mis-run is caused when the metal is unable to fill on the metal while flowing through it.
the mould cavity completely and thus leaves
unfilled cavities, it occurs due to low pouring 1.14 (d)
temperature, lack of fluidity. Chvorinov’s equation;
Y
2
1.7 (a) ⎛V ⎞
Solidification rate = ⎜ ⎟ × k [k = constant]
⎝ A⎠
Pit moulding is used for large job and in
investment casting wax is used and Plaster of 2
t1 ⎛ r1 ⎞
S
Paris or Gypsum (CaSO4 nH2O) is extensively t2 = ⎜⎝ r ⎟⎠
2
used in plaster mould casting.
⇒ t2 = (2)2 × 10 = 40 second
1.8 (a)
A
1.15 (a)
Gravity die casting is used to manufacturing of
aluminium alloy piston. In solidification of metal during casting,
compensation for solid contraction is (shrinkage
1.11 (b)
E allowance) is provided by the oversize pattern.
Silica is used refractory material.
1.12 (a)
A is sprue, it should be tapered down to take
E
into account the gain in velocity of the metal as
it flows reducing the air aspiration.
B is riser, it acts as a reservoir of molten metal is
to be maintained from which the metal can flow
D
readily into the casting when the need arises.

A
M
2 Metal Forming and Sheet
Metal Operations
2.1 Match List-I (Metal forming process) with List

List--II (c) A is true but R is false
Y
(Associated force) and select the correct answer (d) A is false but R is true
using the codes given below the lists: [ESE : 1997]
List-I List-II 2.5 A cup of 10 cm height and 5 cm diameter is to be
A. Wire drawing 1. Shear force made from a sheet metal of 2 mm thickness. The
S
B. Extrusion 2. Tensile force number of deductions necessary will be
C. Blanking 3. Compressive force (a) one (b) two
D. Bending 4. Spring back force
(c) three (d) four
A
Codes:
[ESE : 1997]
A B C D
(a) 4 2 1 3 2.6 Which one of the following processes is most
(b) 2 1 3 4 commonly used for the forging of bolt heads of
(c) 2 3 1 4
E hexagonal shape?
(d) 4 3 2 1 (a) Closed die drop forging
[ESE : 1996] (b) Open die upset forging
(c) Close die press forging
2.2 In wire drawing process, the bright shining surface
(d) Open die progressive forging
on the wire is obtained if one
E
[ESE : 1998]
(a) not using a lubricant
(b) low tooling cost 2.7 The bending force required for V-bending,
(c) uses thick paste lubricant U-bending and Edge-bending will be in the ratio
D
(d) use thin fluid lubricant of

[ESE : 1996] (a) 1 : 2 : 0.5 (b) 2 : 1 : 0.5
(c) 1 : 2 : 1 (d) 1 : 1 : 1
2.3 Which one of the following is an advantage of
[ESE : 1998]
A
forging?
(a) Good surface finish 2.8 Match List-I with List-II and select the correct
(b) Low tooling cost answer using the codes given below the lists:
(c) Close tolerance
M
List-I
(d) Improved physical property
A. Drawing
[ESE : 1996]
B. Rolling
2.4 Assertion (A): In drop forging besides the C. Wire drawing
provision for flash, provision is also to be made D. Sheet metal operations using progressive
in the forging die for additional space called gutter. dies
Reason (R): The gutter helps to restrict the List-II
outward flow of metal thereby helping to fill thin 1. Soap solution
ribs and bases in the upper die. 2. Camber
3. Pilots
explanation of A
4. Crater
5. Ironing
explanation of A
Codes: (b) both A and R are true but R is not a correct

(a) 2 5 1 4 (c) A is true but R is false
(b) 4 1 5 3 (d) A is false but R is true
(c) 5 2 3 4 [ESE : 1999]
(d) 5 2 1 3
[ESE : 1999]
Earing in a drawn cup can be due to non-uniform
2.9 Consider the following operations involved in 1. Speed of the press
forging a hexagonal bolt from a round bar stock, 2. Clearance between tools
Y
whose diameter is equal to the bolt diameter 3. Material properties
1. Flattening 2. Upsetting 4. blank holding
3. Swaging 4. Cambering Which of these statements are correct?
S
The correct sequence of these operations is (a) 1, 2 and 3 (b) 2, 3 and 4
(a) 1, 2, 3, 4 (b) 2, 3, 4, 1 (c) 1, 3 and 4 (d) 1, 2 and 4
(c) 2, 1, 3, 4 (d) 3, 2, 1, 4 [ESE : 1999]
[ESE : 1999]
A
2.13 Assertion (A): In sheet metal blanking operation,
2.10 Which one of the following is the correct clearance must be given to the die.
temperature range for hot extrusion of aluminium? Reason (R): The blank should be of required
(a) 300 – 340°C (b) 350 – 400°C dimensions.
(c) 430 – 480°C (d) 550 – 650°C
E (a) both A and R are true and R is the correct
2.11 Assertion (A): In a two high rolling mill there is a explanation of A
limit to the possible reduction in thickness in one (c) A is true but R is false
E
pass. (d) A is false but R is true [ESE : 1999]
Reason (R): The reduction possible in the second
pass is less than that in the first pass.
D
explanation of A
Answers Metal Forming and Sheet Metal Operations

A
2.1 (c) 2.2 (d) 2.3 (d) 2.4 (c) 2.5 (c) 2.6 (c) 2.7 (a) 2.8 (d) 2.9 (a)
2.10 (c) 2.11 (b) 2.12 (b) 2.13 (d)
Explanations Metal Forming and Sheet Metal Operations

M
2.1 (c) 2.5 (c)

Spring back force is present in bending of sheets. The number of deductions necessary will be three.
2.2 (d) 2.6 (c)

Uses thin fluid lubricant, makes the bright shining Close die press forging
surface.
2.8 (d)
2.3 (d) Camber: As a result of the roll bending the rolled
Improved physical property. strip tends to be thicker (have a crown (at its centre
that at its edges. The usual method of avoiding
this problem is to grind the rolls so that their 2.11 (b)

diameter at the centre is slightly larger than at
Two high or three high rolling mills are used for
their edges by giving them Camber. Thus when
hot rolling in initial break down passes.
the roll bends, contact along the width of the strip
becomes straight and the strip being rolled has a Upper roll
constant thickness along its width.
Ironing: Ironing is a process in which the wall
thickness of a drawn cup is made constant by Lower roll
the pushing of the cup through the Ironing rings.
The space between the rolls can be adjusted by
Y
Craters: are shallow depressions.
the raising or lowering the upper roll. The positions
2.9 (a) of the lower roll is fixed, both the rolls rotate in the
opposite direction to one another. Their direction
The correct sequence of these operations is:
S
of the rotation is fixed and cannot be reversed.
→ Flattening
Thus the work can be rolled by feeding from one
→ Upsetting direction only.
→ Swaging
A
2.12 (b)
→ Cambering
Earing: In drawing the edges of cups may
2.10 (c) become wavy this phenomenon is called as the
earing. The earing condition is caused by the
E
The temperature of the metals in the die are as
planar anisotropy of the sheet.
follows:
(a) 325 to 425°C for Mg 2.13 (d)
(b) 425 to 480°C for Al In the sheet metal blanking operation, clearance
(c) 650 to 900°C for Cu Alloys must be given to the punch.
E
(d) 1100 to 1250°C for Steel
(e) 200 to 250°C for lead
D
A
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3 Joining/Welding
3.1 Consider the following statements: 3.4 The voltage-current characteristics of a dc
Y
MIG welding process uses generator for arc welding is a straight line between
1. consumable electrode an open-circuit voltage of 80 V and short-circuit
2. non-consumable electrode current of 300 A. The generator settings for
3. D.C. power supply maximum arc power will be
S
4. A.C. power supply (a) 80 V & 150 A (b) 40 V & 300 A
Which of these statements are correct? (c) 40 V & 150 A (d) 80 V & 300 A
(a) 2 and 4 (b) 2 and 3 [ESE : 1998]
A
(c) 1 and 4 (d) 1 and 3 [ESE : 1997]
3.5 Which of the following joining processes are best
3.2 Assertion (A): The electrodes of AC arc welding suited for manufacturing pipes to carry gas
are coated with sodium silicate, whereas products?
electrodes used for DC arc welding are coated 1. Riveting 2. Welding
E
with potassium silicate binders. 3. Bolts and nuts
Reason (R): Potassium has a lower ionisation Select the correct answer using the codes given
potential than sodium. below:
(a) both A and R are true and R is the correct (a) 1 and 2 (b) 1 and 3
explanation of A (c) 2 alone (d) 1, 2 and 3
E
(b) both A and R are true but R is not a correct [ESE : 1998]
explanation of A
3.6 In oxy-acetylene gas welding, for complete
combustion, the volume of oxygen required per
D

unit of acetylene is
3.3 An arc welded joint is shown in the above figure. (a) 1 (b) 1.5
The part labelled ‘B’ in the figure is known as (c) 2 (d) 2.5 [ESE : 1998]
A
B 3.7 The correct sequence of the given materials in

ascending order of their weldability is
(a) MS, copper, cast iron, aluminium
M
(b) Cast iron, MS, aluminium copper

(c) Copper, cast iron, MS, aluminium
(a) Weld preparation (b) Penetration (d) Aluminium, copper, cast iron, MS
(c) Reinforcement (d) Slag [ESE : 1998] [ESE : 1999]

Answers Joining/Welding
3.1 (d) 3.2 (d) 3.3 (c) 3.4 (c) 3.5 (c) 3.6 (d) 3.7 (d)
Explanations Joining/Welding
3.1 (d)
⎧ 80 ⎫
Metal inert gas arc welding or more appropriately ∴ V = ⎨80 − I ⎬ volt
⎩ 300 ⎭
called as gas metal arc welding utilizes a
consumable electrode. Normally DC arc welding ⎛ 80 ⎞
P = V I = ⎜ 80 − I⎟ I
machines are used for MIG with electrode ⎝ 300 ⎠
positive. For maximum power;
3.2 (d) dP 80
Y
= 80 − × 2I = 0
The electrodes of AC arc welding are coated with dI 300
potassium silicate binder. It is so because an ∴ I = 150 A and V = 40 V
AC arc must reignite itself when it crosses zero
S
current instant energy 0.01 sec. Reignition 3.5 (c)
require high voltage than normal arc voltage. The
Joining process depends upon type of service
process of reignition if facilitated by presence of
required and welding gives permanent nature of
ions having lower ionization potential and
A
joint and strength being equal to or sometimes
potassium has lower ionization potential. greater than that of parent metal makes welding
one of the most extensively used fabrication
3.3 (c)
method. Leakage is very less in welding.
AR - Reinforcement
E
Ap - Penetration 3.6 (d)
Ap
Dilution = C2H2 + 5 / 2O2 → 2CO2 + H2 O
Ap + AR
1 mole C2H2 requires 2.5 moles of O2
E
AR
B 3.7 (d)
Weldibality signifies the ability of the metal to
D
be welded. It is capacity of metal to be welded

Ap into a specific structure.
Low carbon - excellent weldability
High carbon - poor weldability
A
3.4 (c)
In case of Al main problem is removal of oxide
The voltage-length characteristics of D.C. current
layer, so high costly welding techniques are used.
are is given by

M
4 Machining and Machine
Tool Operation
Directions: The following items consists of two (a) 1 and 2 (b) 2 and 3
Y
statements; one labelled as ‘Assertion (A)’ and the (c) 1 and 3 (d) 1, 2 and 3
other as ‘Reason (R)’
(R)’. You are to examine these two [ESE : 1995]
statements carefully and select the answers to these
4.6 The straight grades of cemented carbide cutting
items using the codes given below:
tool materials contain
S
Codes:
(a) tungsten carbide only
(a) both A and R are true and R is the correct (b) tungsten carbide and titanium carbide
explanation of A (c) tungsten carbide and cobalt
A
(b) both A and R are true but R is not a correct (d) tungsten carbide and coal carbide
4.7 Crater wear is predominant in
E (a) carbon steel tools
4.1 Assertion (A): Non-ferrous materials are best (b) tungsten carbide tools
machined with diamond tools. (c) high speed steel tools
Reason (R): Diamond tools are suitable for high (d) ceramic tools [ESE : 1995]
speed machining. [ESE : 1995] 4.8 Consider the following work materials:
E
4.2 Assertion (A): A chip breaker is employed to 1. Titanium 2. Mild steel
improve the machinability of brass. 3. Stainless steel 4. Grey cast iron
Reason (R): A chip breaker facilitates the curling The correct sequence of these materials in terms
D
and breakage of long continuous chips. of increasing order of difficulty in machining is

[ESE : 1995] (a) 4, 2, 3, 1 (b) 4, 2, 1, 3
(c) 2,4, 3, 1 (d) 2, 4, 1, 3
4.3 The angle between the face and the flank of the [ESE : 1995]
A
single point cutting tool is known as

4.9 The primary tool force used in calculating the total
(a) rake angle (b) clearance angle
power consumption in machining is the
(c) lip angle (d) point angle
(a) radial force (b) tangential force
[ESE : 1995]
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(c) axial force (d) frictional force

4.4 Single point thread cutting tool should ideally [ESE : 1995]
have
4.10 The effects of setting a boring tool above centre
(a) zero rake (b) positive rake
height leads to a/an
(c) negative rake (d) normal rake
(a) increase in the effective rake angle and a
[ESE : 1995] decrease in the effective clearance angle
4.5 Consider the following statements about nose (b) increase in both effective rake angle and
radius effective clearance angle
1. It improves tool life (c) decrease in the effective rake angle and an
2. It reduces the cutting force increase in the effective clearance angle
3. It improves the surface finish (d) decrease in both effective rank angle and
Which of these statements are correct? effective clearance angle [ESE : 1995]
4.11 Assertion (A): Up milling or climb is commonly (b) decreasing the centre distance of bull gear
used for machining castings and forgings. and crank pin.
Reason (R): Up milling can be done on universal (c) increasing the length of the ram.
milling machines. (d) decreasing length of the slot in the slotted
(a) both A and R are true and R is the correct lever. [ESE : 1995]
explanation of A
4.17 While cutting helical gears on a non-differential
gear hobber, the feed change gear ratio is
explanation of A
(a) independent of index change gear ratio
(b) dependent on speed change gear ratio
Y
(c) interrelated to index change gear ratio
4.12 In a milling operation two side milling cutters are (d) independent of speed and index change gear
mounted with a desired distance between them ratio [ESE : 1995]
S
so that both sides of a work piece can be milled 4.18 Match List-I (Task) with List-II (Recommendation)
simultaneously. This setup is called and select the correct answer using the codes
(a) gang milling (b) straddle milling given below the lists:
(c) string milling (d) side milling List-I
A
[ESE : 1995] A. Three components in a straight line should
worked in one loading
4.13 In the grinding wheel of A60 G7 B 23, B stands
B. Unloading of clamp element from jig is
for
(a) resinoid bond (b) rubber bond
E essential
C. Clamping of rough surface
(c) shellac bond (d) silicate bond
D. Need for heavy clamping force
[ESE : 1995]
List-II
4.14 Soft material cannot be economically grounded 1. Clamp with a floating pad
E
due to 2. Quick action nut
(a) the high temperature involved 3. Cam clamp
(b) frequent wheel clogging 4. Equalising clamp
(c) rapid wheel wear 5. Strap clamp
D
(d) low work piece stiffness [ESE : 1995] Codes:

A B C D
4.15 Assertion (A): In a Swiss-type automatic lathe, (a) 5 2 3 4
the turret is given longitudinal feed for each tool
A
(b) 4 2 1 5
in a specific order with suitable indexing. (c) 1 4 2 3
Reason (R): A turret is a multiple tool holder to (d) 4 1 5 3 [ESE : 1995]
facilitate machining with each tool by indexing
4.19 If the diameter of the hole is subject to
M
without the need to change the tools.

(a) both A and R are true and R is the correct considerable variation, then for locating in jigs and
explanation of A fixtures, the pressure type of locator used is
(b) both A and R are true but R is not a correct (a) conical locator (b) cylindrical locator
(c) Diamond pin locator (d) Vee locator
explanation of A
[ESE : 1995]
(d) A is false but R is true 4.20 Chip equivalent is increased by
[ESE : 1995] (a) an increase in side-cutting edge angle of tool
4.16 In a mechanical shaper, the length of stroke is (b) an increase in nose radius and side cutting
increased by edge angle of tool
(a) increasing the centre distance of bull gear (c) increasing the plan area if cut
and crank pin. (d) increasing the depth of cut [ESE : 1996]
4.21 A machinist desires to turn a round steel stock of 4.25 Specific energy requirements in a grinding process
outside diameter 100 mm at 1000 rpm. The are more than those in turning for the same metal
material has tensile strength of 75 kg/mm2. The removal rate because of the
depth of cut chosen is 3 mm at a feed rate of (a) specific pressures between wheel and work
0.3 mm/rev. Which one of the following tool being high.
materials will be suitable for machining the (b) size effect of the larger contact areas between
component under the specified cutting wheel and work.
conditions? (c) high cutting velocities.
(a) Sintered carbides (b) Ceramic (d) high heat produced during grinding.
(c) HSS (d) Diamond [ESE : 1996]
Y
[ESE : 1996]
4.26 A Grinding wheel of 150 mm diameter is rotating
4.22 Which of the following indicate better at 3000 r.m.p. The grinding speed is
machinability? (a) 7.5π m/s (b) 15π m/s
S
1. Smaller shear angle (c) 45π m/s (d) 450π m/s
2. Higher cutting forces [ESE : 1996]
3. Longer tool life
4.27 Grinding wheel is said to be loaded when the
A
4. Better surface finish
(a) Metal particles get embedded in the wheel
(a) 1 and 3 (b) 2 and 4
surface blocking the interspaces between
(c) 1 and 2 (d) 3 and 4
cutting grains.
[ESE : 1996]
E (b) bonding material comes on the surface and
4.23 Which of the following forces are measured the wheel becomes blunt.
directly by strain gauges or force dynamometers (c) work piece being ground comes to a stop in
during metal cutting? cylindrical grinding.
1. Force exerted by the tool on the chip acting (d) grinding wheel stops because of very large
E
normally to the tool face. depth of cut. [ESE : 1996]
2. Horizontal cutting force exerted by the tool
4.28 Which of the following statements are correct?
on the work piece.
1. A boring machine is suitable for a job shop
D
3. Frictional resistance of the tool against the

2. A jig boring machine is designed specially
chip flow acting along the tool face.
for doing more accurate work when compared
4. Vertical force which helps in holding the tool
to a vertical milling machine.
in position.
3. A vertical precision boring machine is suitable
A
(a) 1 and 3 (b) 2 and 4

for boring holes in cylinder blocks and linear.
(c) 1 and 4 (d) 2 and 3
(a) 1, 2 and 3 (b) 1 and 2
[ESE : 1996]
(c) 2 and 3 (d) 1 and 3 [ESE : 1996]
M
4.24 Consider the following statements

4.29 Consider the following processes of gear
The cutter setting block in a milling fixture
manufacture
1. sets the cutting tool with respect of two of its
1. Milling with form cutter
surface.
2. Rack type gear shaper (gear planer)
2. Limits the total travel required by the cutter
3. Rotary gear shaper (gear shaper)
during machining. 4. Gear hobbing
3. Takes location from the location scheme of The correct sequence of these processes in
component. increasing order of accuracy of convolute profile
Which of these statements are correct? of the gear is
(a) 1, 2 and 3 (b) 1 and 2 (a) 3, 2, 4, 1 (b) 2, 3, 4, 1
(c) 2 and 3 (d) 1 and 3 (c) 3, 2, 1, 4 (d) 2, 3, 1, 4
[ESE : 1996] [ESE : 1996]
4.30 Gear cutting on a milling machine using an 4.35 Which of the following is/are the advantage(s) of
involute profile cutter is a numerical control of machine tools?
(a) gear forming process. 1. Reduced lead time
(b) gear generating process. 2. Consistently good quality
(c) gear shaping process. 3. Elaborate Fixtures are not required
(d) highly accurate gear producing process. Select the correct answer using the codes given
[ESE : 1996] below:
Codes:
4.31 For the manufacture of full depth spur gear by
(a) 2 and 3 (b) 1 and 2
hobbing process, the number of teeth to be
Y
(c) 1 alone (d) 1 and 3
cut = 30, module = 3 mm and pressure angle = 20°.
[ESE : 1996]
The radial depth of cut to be employed should be
equal to 4.36 In orthogonal cutting, the depth of cut is 0.5 mm
S
(a) 3.75 mm at a cutting speed of 2 m/s. If the chip thickness
(b) 4.50 mm is 0.75 mm, the velocity is
(c) 6.00 mm (a) 1.33 m/s (b) 2 m/s
(d) 6.75 mm (c) 2/5 m/s (d) 3 m/s [ESE : 1997]
A
[ESE : 1996]
4.37 Consider the following elements
4.32 Assertion (A): Special purpose machine tools can 1. Nose radius 2. Cutting speed
do special types of machining work automatically. 3. Depth of cut 4. Feed
E
Reason (R): Vertical boring machine is an The correct sequence of these elements in
example of special purpose machine tool. DECREASING order of their influence on tool life
(a) both A and R are true and R is the correct is
explanation of A (a) 2, 4, 3, 1 (b) 4, 2, 3, 1
E
(c) 2, 4, 1, 3 (d) 4, 2, 1, 3
(d) A is false but R is true 4.38 The rake angle in a twist drill
D
[ESE : 1996] (a) varies from minimum near the dead centre to
a maximum value at the periphery.
4.33 Internal gears can be made by
(b) is maximum at the dead centre and zero at
(a) hobbing
the periphery.
A
(b) gear shaping with rack cutter (c) is constant at every point of the cutting edge.
(c) gear shaping with pinion cutter (d) is a function of the size of the chisel edge.
(d) gang milling [ESE : 1997]
[ESE : 1996]
M
4.39 Consider the following statement with respect to

4.34 A s s e r t i o n ( A ) : A workpiece with rough relief angle of cutting tool
unmachined surface can be located in a jig or 1. This affects the direction of chip flow
fixture on three supporting points. 2. This reduces excessive friction between the
Reason (R): Indexing is made accurate by tool & work piece.
supporting on three points. 3. This affects tool life.
(a) both A and R are true and R is the correct 4. This allow better access of coolant the tool-
explanation of A workpiece interface.
(b) both A and R are true but R is not a correct Which of these statements are correct?
explanation of A (a) 1 and 2 (b) 2 and 3
(c) A is true but R is false (c) 2 and 4 (d) 3 and 4
(d) A is false but R is true [ESE : 1996] [ESE : 1997]
4.40 Assertion (A): Ceramic tools are used only for (a) 2, 3, 4, 1 (b) 3, 2, 4, 1
light, smooth and continuous cuts at high speeds. (c) 2, 3, 1, 4 (d) 3, 2, 1, 4
Reason (R): Ceramics have a high wear [ESE : 1997]
resistance and high temperature resistance.
4.45 Which of the following motions are not needed for
spur gear cutting with a hob?
explanation of A
1. Rotary motion of hob.
2. Linear axial reciprocatory motion of hob?
explanation of A
3. Rotary motion of gear blank.
4. Radial advancement of hob.
Y
4.41 Consider the following statements: below:
In Up milling process, (a) 1, 2 and 3 (b) 1, 3 and 4
1. the cutter starts the cut from the machined (c) 1, 2 and 4 (d) 2, 3 and 4
S
surface and proceeds upwards. [ESE : 1997]
2. the cutter starts the cut from the top surface
4.46 Match List-I (Gear component) with List-II
and proceeds downwards
(Preferred method of manufacturing) and select
A
3. the job is fed in a direction opposite to that of
the correct answer using the codes given below
cutter rotation.
the lists:
4. the job is fed in the same direction as that of
List-I
cutter rotation.
A. Gear for clocks
E
B. Bakelite gears
(a) 1 and 3 (b) 1 and 4
C. Aluminium gears
(c) 2 and 3 (d) 2 and 4 [ESE : 1997]
D. Automobile transmission gears
4.42 Which one of the following materials is used as List-II
the bonding material for grinding wheels? 1. Hobbing
E
(a) Silicon carbide (b) Sodium silicate 2. Stamping

(c) Boron carbide (d) Aluminium oxide 3. Powder compacting
[ESE : 1997] 4. Sand casting
D
5. Extrusion
4.43 Which of the following are the advantages of a
Codes:
hydraulic shaper over a mechanically driven
A B C D
shaper?
(a) 2 3 5 1
A
1. More strokes per minute can be obtained at

(b) 5 3 4 2
a given cutting speed.
(c) 5 1 2 3
2. The cutting stoke has a definite stopping point.
(d) 2 4 5 3 [ESE : 1997]
3. It is simpler in construction
M
4. Cutting speed is constant throughout most 4.47 Assertion (A): In a slow speed high pressure
of the cutting stroke. metal cutting process such as gear cutting,
Select the correct answer using the codes given chlorinated or sulphonated oils are used.
below: Reason (R): Reduction of coefficient of friction
(a) 1 and 2 (b) 1 and 4 is achieved by the formation of a solid film at the
(c) 2 and 4 (d) 1, 3 and 4 rubbing interface of tool and chip.
[ESE : 1997] (a) both A and R are true and R is the correct
explanation of A
4.44 Consider the following operations:
1. Under cutting 2. Plain turning
explanation of A
3. Taper turning 4. Thread cutting
The correct sequence of these operations in
machining a product is:
4.48 Consider the following statement:

During third stage of tool-wear, rapid deterioration
Production Rate
Variables Cost,
of tool edge takes place because Variables Cost
1. Flank wear is only marginal
2. Flank wear is large Production Rate
3. Temperature of tool increase gradually
4. Temperature of tool increase drastically
1 2 34 5
(a) 1 and 3 (b) 2 and 4 Cutting Speed
(c) 1 and 4 (d) 2 and 3
(a) 1 and 3 (b) 1 and 5
Y
[ESE : 1998]
(c) 2 and 4 (d) 3 and 5 [ESE : 1998]
4.49 In metal cutting operation, the approximate ratio
4.53 Consider the following criteria in evaluating
heat distributed among chip, tool and work, in
machinability
S
that order is 1. Surface finish
(a) 80 : 10 : 10 2. Type of chips
(b) 33 : 33 : 33 3. Tool life
A
(c) 20 : 60 : 10 4. Power consumption
(d) 10 : 10 : 80 In modern high speed CNC machining with coated
[ESE : 1998] carbide tools, the correct sequence of these
criteria in DECREASING order of their importance is
E
4.50 Poor machinability of centrifugally cast iron pipe
(a) 1, 2, 4, 3 (b) 2, 1, 4, 3
is due to
(c) 1, 2, 3, 4 (d) 2, 1, 3, 4
(a) Chilling
[ESE : 1998]
(b) Segregation
(c) Dense structure 4.54 Which one of the following pairs of parameters
E
(d) High mould rotation speed [ESE : 1998] and effects is not correctly matched?
(a) Large wheel diameter ... Reduced wheel wear
4.51 On a lathe, the actual machining time required
(b) Large depth of cut ... Increased wheel wear
per work piece is 30 minutes. Two types of carbide
D
(c) Large work diameter... Increased wheel wear

tools are available, both having a tool life of (d) Large wheel speed... Reduced wheel wear
60 minutes. [ESE : 1998]
Type-I : Brazed type of original cost Rs. 50/-
A
Type-II : Throw away tip (square) of original cost 4.55 The gauge factor of a resistive pick-up of cutting
Rs. 70/- force dynamometer is defined as the ratio of
If the overall cost of grinding the cutting edge is (a) Applied strain to the resistance of the wire
(b) The proportional change in resistance to the
Rs. 10/-, assuming all the costs are the same for
M
applied strain
both the types, for break even costs, the
(c) The resistance to the applied strain
appropriate batch size would be
(d) Change in resistance to the applied strain
(a) 2 pieces (b) 4 pieces
[ESE : 1998]
(c) 6 pieces (d) 8 pieces
[ESE : 1998] 4.56 A 400 mm long shaft has a 100 mm tapered step
at the middle with 4° included angle. The tailstock
4.52 The variable cost and production rate of a
offset required to produce this taper on a lathe
machining rate of a machining process against
would be
cutting speed are shown in the given figure. for (a) 400 sin 4° (b) 400 sin 2°
efficient machining the range of best cutting (c) 100 sin 4° (d) 100 sin 2°
speed would be between [ESE : 1998]
4.57 Match List-I with List-II and select the correct 4.60 Which one of the following sets of forces are
answer using the codes given below the lists: encountered by a lathe parting tool while groove
List-I cutting?
A. Reaming (a) Tangential, radial and axial
B. Counter-boring (b) Tangential and radial
C. Counter-sinking (c) Tangential and axial
D. Spot facing (d) Radial and axial
List-II [ESE : 1999]
1. Smoothing and squaring surface around the 4.61 In a single-point turning operation of steel with a
Y
hole for proper seating cemented carbide tool, Taylor’s tool life exponent
2. Sizing and finishing the hole is 0.25. If the cutting speed is halved, the tool life
3. Enlarging the end of the hole will increase by
4. Making a conical enlargement at the end of
S
(a) Two times (b) Four times
the hole (c) Eight times (d) Sixteen times
Codes: [ESE : 1999]
A B C D
A
(a) 3 2 4 1 4.62 Consider the following approaches normally
(b) 2 3 1 4 applied for the economic analysis of machining
1. Maximum productions rate
(c) 3 2 1 4
2. Maximum profit criterion
(d) 2 3 4 1
E 3. Minimum cost criterion
[ESE : 1998]
The correct sequence in ascending order of
4.58 A component requires a hole which must be within optimum cutting speed obtained by these
the two limits of 25.03 and 25.04 mm diameter. approaches is:
Which of the following statement about the reamer (a) 1, 2, 3 (b) 1, 3, 2
E
size are correct? (c) 3, 2, 1 (d) 3, 1, 2

1. Reamer size cannot be below 25.03 mm [ESE : 1999]
2. Reamer size cannot be above 25.04 mm
4.63 Match List-I (ISO classification of carbide tools)
D
3. Reamer size can be 25.04 mm

with List-II (Applications) and select the correct
4. Reamer size can be 25.03 mm.
Select the correct answer using the code given
below: List-I
A
(a) 1 and 3 (b) 1 and 2 A. P – 10

(c) 3 and 4 (d) 2 and 4 B. P – 50
[ESE : 1998] C. K – 10
M
D. K – 50
4.59 Assertion (A): Internal gears are cut on a gear
List-II
shaper. 1. Non-ferrous, roughing cut
Reason (R): Hobbing is not suitable for cutting 2. Non-ferrous, finishing cut
internal gear. 3. Ferrous material, roughing cut
(a) both A and R are true and R is the correct 4. Ferrous material, finishing cut
explanation of A Codes:
(b) both A and R are true but R is not a correct A B C D
explanation of A (a) 4 3 1 2
(c) A is true but R is false (b) 3 4 2 1
(d) A is false but R is true (c) 4 3 2 1
[ESE : 1998] (d) 3 4 1 2 [ESE : 1999]
4.64 Consider the following statements: 4.69 Match List-I (Drill bits) with List-II (Applications)
For precision machining of non-ferrous alloys, and select the correct answer using the codes
diamond is preferred because it has: given below the lists:
1. Low coefficient of thermal expansion List-I
2. High wear resistance A. Core drill
3. High compression strength B. Reamer
C. Counter bore drill
4. Low fracture toughness
D. Tap drill
List-II
(a) 1 and 2 (b) 1 and 4
1. To enlarge a hole to a certain depth so as to
Y
(c) 2 and 3 (d) 3 and 4
accommodate the bolt head of a screw
[ESE : 1999] 2. To drill & enlarge an already existing hole in a
4.65 In turning operation, the feed could be doubled casting
3. To drill a hole before making internal thread
S
to increase the metal removal rate. To keep the
4. To improve the surface finish and dimensional
same level of surface finish, the nose radius of
accuracy of the already drilled hole
the tool should be
Codes:
(a) Halved
A
A B C D
(b) Kept unchanged
(a) 1 3 2 4
(c) Doubled
(b) 2 3 1 4
(d) Made four times (c) 2 4 1 3
E
[ESE : 1999] (d) 3 2 4 1 [ESE : 1999]
4.66 The radial force in single-point tool during turning 4.70 Which one of the following processes results in
operation varies between the best accuracy of the hole made?
(a) 0.2 to 0.4 time the main cutting force (a) Drilling (b) Reaming
(b) 0.4 to 0.6 times the main cutting force (c) Broaching (d) Boring [ESE : 1999]
E
(c) 0.6 to 0.8 times the main cutting force 4.71 Consider the following statements regarding
(d) 0.5 to 0.6 times the main cutting force reaming process:
[ESE : 1999] 1. reaming generally produces a hole larger than
D
4.67 A straight teeth slab milling cutter of 100 mm its own diameter
2. Generally rake angels are not provided on
diameter and 10 teeth rotating at 200 rpm is used
reamers.
to remove a layer of 3 mm thickness from a steel
3. Even numbers of teeth are preferred in reamer
A
bar. If the table feed is 400 mm/minute, the feed

design.
per tooth in this operation will be
(a) 0.2 mm (b) 0.4 mm (a) 1 and 2 (b) 2 and 3
(c) 0.5 mm (d) 0.6 mm
M
(c) 1 and 3 (d) 1, 2 and 3

[ESE : 1999] [ESE : 1999]
4.68 Consider the following reasons 4.72 A 60-teeth gear when hobbed on a differential
1. Grinding wheel is soft hobber with a two-start hob, the index change
2. RPM of grinding wheel is too low gear ratio is governed by which one of the
3. Cut is very fine following kinematic balance equations?
4. An improper cutting fluid is used (a) 1 revolution of gear blank = 1/60 of hob
A grinding wheel may become loaded due to revolutions
reasons stated at (b) 1 revolution of gear blank = 2/60 of hob
(a) 1 and 4 (b) 1 and 3 revolutions
(c) 2 and 4 (d) 2 and 3 (c) 1 revolution of hob = 2/60 of blank revolutions
(d) 1 revolution of hob = 1/60 of blank revolutions
[ESE : 1999]
[ESE : 1999]
4.73 Diamond pin location is used in a fixture because Reason (R): 3 – 2 – 1 principle should be adopted
(a) It does not wear out to locate the job.
(b) It takes care of any variation in centre distance (a) both A and R are true and R is the correct
between two holes explanation of A
(c) It is easy to clamp the part on diamond pins (b) both A and R are true but R is not a correct
(d) It is easy to manufacture [ESE : 1999] explanation of A
4.74 Assertion (A): Spherical washers are used to
locate the job in the fixtures.

Y
Answers Machining and Machine Tool Operation
4.1 (b) 4.2 (d) 4.3 (c) 4.4 (a) 4.5 (c) 4.6 (c) 4.7 (b) 4.8 (a) 4.9 (b)
S
4.10 (c) 4.11 (d) 4.12 (b) 4.13 (a) 4.14 (b) 4.15 (b) 4.16 (a) 4.17 (c) 4.18 (d)
4.19 (a) 4.20 (b) 4.21 (b) 4.22 (d) 4.23 (b) 4.24 (d) 4.25 (b) 4.26 (a) 4.27 (a)
4.28 (a) 4.29 (d) 4.30 (b) 4.31 (d) 4.32 (b) 4.33 (c) 4.34 (c) 4.35 (a) 4.36 (a)
A
4.37 (a) 4.38 (a) 4.39 (b) 4.40 (b) 4.41 (a) 4.42 (b) 4.43 (c) 4.44 (a) 4.45 (a)
4.46 (a) 4.47 (a) 4.48 (d) 4.49 (a) 4.50 (c) 4.51 (a) 4.52 (c) 4.53 (c) 4.54 (c)
4.55 (b) 4.56 (b) 4.57 (d) 4.58 (b) 4.59 (b) 4.60 (a) 4.61 (d) 4.62 (c) 4.63 (c)
E
4.64 (a) 4.65 (d) 4.66 (a) 4.67 (a) 4.68 (c) 4.69 (c) 4.70 (b) 4.71 (b) 4.72 (c)
4.73 (b) 4.74 (d)
Explanations Machining and Machine Tool Operation

E
4.1 (b) 4.3 (c)
Diamond tools have low tool-chip friction, high Lip angle is defined as the angle between the
D
wear resistance and ability to maintain a sharp face and flank of the tool.
cutting edge and are used for high speed
machining of non ferrous material (Al, Cu, brass face
of bronze or where silicon content is more). Non
A
ferrous material generally have continuous chip lip angle

formation. Feed rate is kept low. flank
While machining ferrous material they have
M
strong chemical affinity for it so not recommended

4.4 (a)
for ferrous material.
4.2 (d) It is true form-cutting procedure, no rake should

be ground on the tool, and the top of the tool
Machinability of a material depends upon the must be horizontal and be set exactly in line with
property of material by which the ease with which the axis of rotation of the work; otherwise, the
it can cut to give better surface, tool life obtained. resulting thread profile will not be correct. An
Force and power requirement, chip control (As obvious disadvantage of this method is that the
for chip control, long and thin, curved chip should absence of side and back rake results in poor
be produced itself). For brass, the chip produced cutting (except on cast iron or brass). The surface
is discontinuous so no use of chip breaker. finish on steel usually will be poor.
4.5 (c) In universal milling machine table is placed on

the swivel and the swivel is placed on the saddle.
Large nose radius gives better surface finish and Because of the swivel, the table and hence the
improves tool life. job can be fixed at desired angle, so that inclined
However cutting force and possibility of chatter cuts can be taken and hence the job can be fixed
increases when the nose radius is increased. at desired angle, so that inclined cuts can be
taken and hence the helical gear and drilling
4.6 (c )
flutes are easily cut by the machine.
Y
Tungsten 4.13 (a)
Straight tungsten Alloyed tungsten
A 60 G 7 B 23
carbide carbide
(powder Alloyed tungsten 1 2 3 4 5 6
S
metallurgy) carbide has 1. Abrasive type A – aluminium oxide,
addition of carbide C – Silicon carbide
of titanium and
2. Abrasive grain size, 60 – Medium
niobium etc.
A
(85–97 tungsten 3. Grade A (Soft) - to z (hard)
carbide) + cobalt 4. Structure 1 (Dense) to 16 (Open)
(5– 15%) which 5. Bond type B-Resinoid, R-Rubber,
acts as bonding E- Shellac, S-Silicate
agent
E 6. Manufacturer’s record
4.14 (b)
4.7 (b)
Soft material can not be economically grinded
Tungsten carbide tool: because when the
because ductile nature (small chips produced
E
interface temperature is high then the carbides
and get clogged in between randomly oriented
disintegrate (wc → w + c) and carbon diffuses
teeth).
to the softer matrix of machining part, this
D
phenomena reduces the strength of tool and after 4.15 (b)

some time it dislodges it. Swiss type they are designed for machining long
accurate part of small diameter (4 to 25 mm). An
4.9 (b)
exclusive feature of these machine is the
A
Tangential force because power consumption is longitudinal travel of head stock or of a quite
Fc.V (cutting force × cutting velocity). carrying the rotating work spindle.
The main characteristic of turret lathe is 6-sided
4.10 (c)
M
block mounted on one end of the bed replacing

The effect of setting a boring tool above centre tail stock this allow mounting six tool block each
height leads to an decrease in rake angle and one of then containing one or more tool according
increase in effective clearance angle. to requirement thus total tool carrying capacity
is 14 tools.
4.11 (d)
4.16 (a)
Climb milling (Up milling) is not suitable for
machining of workpiece having surface scale Shaper makes use of a single point tool that
such as hot-worked metals, forging and casting. transverse the work and feed once at the end of
The scale is hard and abrasive causes excessive each stroke. Since amount of metal removed at
wear and damage to the cutter teeth, shortening one time is relatively small in area, therefore little
its life. pressure is imposed upon work and elaborate
holding fixtures are not needed. Shaper is very 4.18 (d)

well suited for contour work which is done by
Equalizing Clamp: Three components in a
coordinating the tool hand feed to a layout line
straight line should working in one loading.
or by a duplicating attachment placed on Clamp with a floating pad: unloading of clamp
machine like deep internal slot and difficult element ram jig is essential.
contours. Strap clamp: Clamping of rough surface.
It occupies less space, consumes less power,
Cam Clamp: Need for heavily clamping force.
cost less, occupies less floor area, is easier to
operate and about three times quicker in action. 4.19 (a)
It gets its drive from the quick return mechanism
Y
Locator: Application.
which makes it run faster while returning and Conical locator: These are used to locate a work
slower while cutting. The size of shaper is given piece which is cylindrical and with or without a
by maximum length of stroke or ram movement. hole.
S
Size varying from 175 to 900 mm stroke. Cylindrical locator: In these, the locating
The length of stroke can be increased by diameter of the pin is made a push fit with the
increasing the centre distance of bull gear and hole in the workpiece.
A
crank pin. Diamond pin locator: These are used to
constrain the pivoting of the workpiece around
4.17 (c)
the principal location
Helical teeth are to be cut, the axis of hob can V -locator: These are used, in circular and
E semicircular profile.
be set over at an angle to produce the proper
helix. The hob axis is set at angle equal to helix
4.20 (b)
angle of thread in reference to the axis of gear
blank. This brings the blank teeth in the plane of According to Colding’s equation:
hob’s teeth. This plane is termed as generating Engaged cutting edge length
E
q=
plane. The cutter finishes all the teeth in one pass Plan area of cut
over the work. [d − rn (1 − sin γ s )]
Work table and hob have to rotate in definite [cos γ s + (π / 2 − γ s )rn + f / 2]
=
D
relationship obtained by index change gear fd

formula is: where
γs = side cutting edge angle
Number of teeth on index change gear
f = feed rate; d = depth of cut; rn = nose radius
A
Number of teeth on index gear

When side cutting edge angle is increased, the
chip equivalent q as well as area of chip tool
Indexing constant × Number of teeth of hob
contact is increased without significantly
Number of teeth to be cut
M
changing the cutting the forces. Increase in nose

For hobbing helical gear the rotation of work table
radius increases the value of chip equivalent q
is slightly advanced or retarded in relation to
and improves life. Increases in nose radius also
rotation of axial feed screw by means of another
increases the value of chip equivalent q from
set of change gear called differential change
above equation.
gears. The differential change gears are
calculated to satisfy the following basic relations
between axial feed screw and work table rotation.
Tool life
Tool life
Revolution of axial feed screw × lead of axial

Optimum
feed screw = additional revolution of work table rake
× Lead of work piece helix. 0 +ve
–ve Relief angle
4.21 (b) 4.26 (a)

Ceramic because ceramic tool should be used πDN π × 150 × 3000
for low depth of cut and low feed rate but at very V = = = 7.5 π m/s
60 60 × 1000
high speed, cutting takes place.
4.27 (a)
4.22 (d) Grinding wheel is said to be loaded when the
Larger shear angle implies Fc will be more metal particles get embedded in the wheel
surface blocking the interspaces between cutting
bt1 cos(β − α)
Fc = Fs ⋅ Fc ↑ as φ ↓ grains. Loading is generally caused during the
sin φ cos(φ + β − α)
Y
grinding of soft and ductile materials. A loaded.
Good machinability indicates good surface finish grinding wheel cannot cut properly. Such a
and integrity, long tool life, low force and power grinding wheel can be cleared and sharpened
requirement and easy collection of chips that
S
by means of process called dressing.
does not interfere with the cutting operations.
4.28 (a)
4.23 (b)
JIG Boring Machines
Machines: These are precision
A
boring machines having precision spindles and
FH N
slides. These are used for machining drilling,
A boring of precision components as well as for
Fv
E making tools and dies for press work and
B machining of components for jigs and fixtures
r etc. The machines are generally equipped with
high precision optical scales for motion
The tangential force and axial component along
measurement of every slide. For high accuracy
the tool is measured. For any cutting process it
E
the machines should be kept in a clean and
is desirable to measure the three force
temperature controlled (air- conditioned)
components in a set of rectangular coordinates.
environment.
While measuring these three forces, the
Vertical precision boring are used to machine
D
dynamometer should be so designed that force

inside and outside diameters of large pipes and
in x-direction should give no reading in y and
pressure vessels. Since boring machines are very
z-directions, i.e., there be no cross-sensitivity.
heavy and big i.e., Standard vertical boring
A
4.24 (d) machine is largest of machine tool so boring

machine are kept at job shops.
Cutter setting block sets the workpiece in correct
relationship with cutter with the help of filler gauge 4.29 (d)
M
Cutter setting block also gives correct correlation

Planer < Shaper < Milling with form cutter <
(location) for milling operation.
Hobbing
4.25 (b)
4.30 (b)
Grinding process is a very inefficient one
Gear cutting on a milling machine using an
compared to the conventional metal cutting
involute profile cutter is a gear generating process.
process.
Form cutting : Such as gear milling broaching.
Specific energy of grinding = 50 J/mm3
Generation : Which generate the involute
Specific energy of other = 2 to 5 J/mm3
surface of gear teeth.
A large number of cutting edges are involved in
Forming : Which form gear teeth by
cutting this result in large contact area between plastic deformation of the work
wheel and work. material.
4.31 (d) 4.38 (a)

Radial depth of cut = Tooth depth (h) Normal rake angle α at a distance r from center
Tooth depth (h) = 2.25 m is given by
= 2.25 × 3 = 6.75 mm
⎡ ⎛ 2r ⎞ ⎤
4.33 (c) ⎢ ⎜⎝ D ⎟⎠ tan ψ ⎥
−1
α = tan ⎢ ⎥
Internal gears will be made by gear shaping with ⎣⎢ sin β ⎦⎥
pinion cutter.
where ψ = helix angle, β = halfpoint angle
Y
4.34 (c) ‘r’ being the radius of the point on the cutting
Indexing Jigs and Fixtures are used when holes edge where the normal rake is being evaluated.
or slots are to be machined to some specific
relationship, in a work piece. 4.39 (b)
S
The relief is provided to side and end flanks in
4.35 (a)
order to minimize physical interference or rubbing
Numerical control has following advantages over contact with the machined surface of workpiece.
A
conventional method of machines control:
It is prescribed to use smaller relief angle when
1. Flexibility of operation is improved, as well
either the tool material is brittle or workpiece has
as the ability to produce compex shapes with
high tensile strength or both because small relief
good dimensional accuracy, good
E do not weaken cutting edge.
repeatability, reduced scrap loss, high
Increased relief angle provide a cleaner cut and
production rates, high productivity, and high
reducing the friction at the flank causing reduction
product quality.
in cutting force.
2. Tooling costs are reduced, because
E
templates and other fixtures are not 4.40 (b)
required
required. Ceramic tools are used only for light smooth and
3. More operation can be performed with each continuous cut at high speed because they are
D
setup, and the lead time for setup and brittle and have poor shock resistance. Since
machining required is less
less, as compared to they contain pure aluminium oxide (97%) and
conventional method. carbides they are very hard and have good
resistance to abrasion wear and cratering. The
A
4.36 (a) main problem with ceramic tools are their low
Volume of metal removal. strength, poor thermal characteristic and their
l1b1t1 = l2b2t 2 (mm3 ) tendency towards chipping.

M
4.41 (a)
V1b1t1 = V2 ⋅ b2 ⋅ t2 (mm3 / s) b1 = b2
∵ no side flow Machined surface
Up milling
t1 2 × 0.5
V2 = V1 ⋅ = = 1.33 m/s
t2 0.75
Cutter starts the cut from the machined surface

4.37 (a)
and proceeds upwards and the job is fed in a
Effect on tool life direction opposite to that of cutter rotation.
V > f > d > nose radius
4.42 (b) blank. Bakelite and other plastic materials are

the most commonly used materials for
Sodium silicate is bonding material, while other
three are abrasive particles, other examples of manufacture of gear by this method.
bonds are: 4.48 (d)
Vitrified, Synthesis, Resin, Rubber, Shellac
The wear land is not of uniform width. It is widest
Vitrified: This is actually clay mixed with fluxes
at a point farthest from the nose. This is due to
such as feldspar, which harder to glass like
the fact that the material cut by this part of cutting
substance on firing to a temperature of about
edge had been work hardened during the
1250°C and develops the strength. previous cut. The frictional stress and maximum
Y
temperature at the flanks also go on increasing
4.43 (c)
with time.
Hydraulic mechanism are becoming increasingly
Constant rate Rapid wear
popular because of the following advantages: wear region
S
Initial C
Width of flank wear

(a) Greater flexibility of speed rapid wear
(b) Smoother operation. B
A
(c) Possibility of changing speed and feed
A
during operation
(d) Velocity diagram of hydraulically operated
shaper-shows a very nearly constant velocity
0 Time
as compared with the crank shaper
E
A stage is reached when diffusion becomes the
Forward stroke
predominant wear mode on the flank. After a
critical wear land has formed, further wear takes
Velocity
Displacement
place at an accelerating rate.
E
4.49 (a)
Return stroke
Maximum heat is carried away by chip, tool and
In one stroke it moves at low speed and in
workpiece share almost equal heat i.e., 10% each
D
opposite stroke it moves at high speed.

while chip contains 80% of total heat.
4.44 (a)
4.51 (a)
Plain turning → Taper turning → Thread cutting
One tool of both the types produces two pieces.
A
→ Under cutting. Now if break even point is ‘n’ number of pieces

then:
4.45 (a)
In spur gear cutting, Rotary motion and axial feed
M
is given to hob. Gear blank is given Rotary

motion. Linear axial reciprocatory motion is given n
50 + 10 ×
2
to hob. n
70 ×
2
4.46 (a) 50
Gear of clocks are made by stamping. Materials

up to 3mm thickness are practical for this ⎛ n⎞ n
50 + 10 × ⎜ ⎟ = × 70
process. ⎝ 2⎠ 2
Powder Compacting: In this process a master
⇒ 50 + 5n = 35n
gear of hard material is rolled against a heated
gear-blank, thereby forming the teeth on the hot 5
⇒ n= = 1.667 2
3
4.52 (c) 4.54 (c)

Our main interest is in producing the components Grinding wheel wear is generally correlated with
at maximum rate and at minimum cost. For this, the amount of work piece material ground by a
we adopt the minimum cost and maximum parameter called the grinding ratio, G, which is
production curves as shown in figure. While defined as
observing this diagram we find that the cutting Volume of material removed
speed (V0) at which the total production cost in G=
Volume of wheel wear
minimum, is not the same as that at which the
⎛v d⎞
production rate is maximum. The former is less Grain force ∝ ⎜
⎝V D ⎟⎠
Y
than the latter. The area lying in between these
two values of cutting speeds is knows as “High [Strength of the material]
Efficiency Range” (Hi-E Range) and the cutting where, v – Velocity of work piece
speeds lying in this range are either economical d – Depth of cut
S
or more productive. For efficient and economical V – Speed/velocity of grinding wheel
production of a workpiece the cutting speed D – Diameter of grinding wheel
should always be selected from within the range The higher the force, the greater the tendency
A
only. for the grains to fracture or be dislodged from
the wheel surface, and the higher the wheel wear
and the lower the grinding ratio.
Total time per piece
We note that the grain force increases with the
E strength of the work piece material, work speed
minimum and depth of cut, and decreases with increasing
time Tool changing time
Total time per piece
maximum Tool regrinding time

wheel speed and wheel diameter. Thus a wheel
production acts soft when v and d increase or when V and
Pm
D decrease.
E
Non-Production time
4.56 (b)
Vmp B
d1 d2 – d1
D
Cutting speed d2 α
C A 2l
l
A
The offset can be calculate as follows:

minimum
cost maximum
p BC
sin α =
Cost per piece
production
AB
Hi-E pieces per
S = AB sin α = L sin α
M
Range unit time
If α is very small, then we can approximate

Taper
V0 Vmp angle = 2α
Cutting speed Tail stock set over
α
4.53 (c)
The main criteria of using CNC machine is to
achieve closer dimensional tolerance (Better
surface finish most important criteria) Surface
finish > Type of chip > Tool life > Power ⎛ α⎞ ⎛ α⎞ D −d
sin ⎜ ⎟ = tan ⎜ ⎟ =
consumption. ⎝ 2⎠ ⎝ 2⎠ 2l
(D − d ) 4.61 (d)
S =L
2l n n
1 1 = V2T2
VT
This is most general situation where taper is to V 0.25
be limited and as such this method is suitable VT 0.25 =
2
T2 [2]4 ⋅ T = T2
for small taper over a long length. The
T2 = 16T
disadvantage is that the centres would not be
properly bearing in the centre hole and as such T = Tool life increased by sixteen times.
there would be nonuniform wearing.
4.62 (c)
Y
D −d At the cutting speed for minimum cost, the
S =L×
2l production rate may be too low to maximize profit
rate while at the cutting speed for maximum
⎛ α⎞ D − d
sin ⎜ ⎟ = production rate, the cost of production may be
S
⎝ 2⎠ 2l
too high and hence profit margin is too low
∴ S = 400 sin2° Vopmincost < Vopmaxprofit < Vop max prodution
A
4.57 (d)
4.63 (c)
Reaming: It is operation of sizing and finishing
a already existing hole. A-4; B-3; C-2; D-1
Counter -boring : The hole is enlarged with a
Counter-boring P-10 Ferrous material finishing cut
E P-50 Ferrous material, roughening
flat bottom to provide a proper seating for bolt
head or nut. K-10 Non ferrous, finishing cut
Countersinking: Similar to counter boring K-50 Non ferrous, roughening cut
additional machining done on a hole is conical
4.64 (a)
E
to accommodate the counter sink machine screw
head. Diamond has lowest thermal expansions (12%
Spot facing: Similar to counter boring but that of steel) High heat conductivity (2 times that
removes very small portion of material. of steel) very low coefficient of friction against
D
metal and poor electrical thermal conductivity.

4.58 (b) So they are used to machine soft materials
The reamer drill size to be selected for a particular (nonferrous metal) for production of high surface
A
hole should be in limit less in size than the finish finish.

size of hole. 4.65 (d)
4.59 (b) f2
Hmax =
M
A gear shaping pinion cutter is used by which 8r

one can cut internal gear. Hobbing has a hob where f is feed rate and r is nose radius
tool which is worm like or thread like cutter which Hmax ∝ f 2
is fed axially along the gear so not possible to
make internal gear. 1
∝
r
4.60 (a)
f12
In case of groove cutting, the tool is set on centre (Hmax )1 = k ×
r1
and fed in until it just touches the work surface.
The three component tangential, radial and axial (2f1 )2
will arise. (Hmax )2 = k ×
r2
∴ (Hmax )1 = (Hmax )2 4.70 (b)

r2 = 4r1 Reaming is the process in which surface finish
and dimensional accuracy is improved whereas
4.66 (a) boring make the hole true.
Ft for turning varies between 0.3Fc to 0.6Fc
4.71 (b)
Fr for turning varies between 0.2Fc to 0.4Fc
Straight reamers type produce better finish due
4.67 (a) to smooth shear cutting. The flutes on reamer
f = fT × Z × N where f = Table feed; body act both as cutting teeth and a grooves for
accommodating chips removed. The size of
Y
fT = feed/tooth; Z = Number of teeth
reamer is specified by diameter measured
N = RPM
across two margins, at the cutting edge on
∴ 400 = fT × 10 × 200
diametrical line. Number of flutes is usually even.
400
S
⇒ fT = = 0.2 mm
2000 4.73 (b)
4.69 (c) Diamond pin location is used in fixture because
Tap drill: These are used for enlarging and it takes care of any variation in centre distance
A
correcting the location of previously made holes between two holes.
as their cutting edges do not extend upto the
centre. 4.74 (d)
E
Flat drill: It is preferred for drilling soft material Spherical washers are used to locate the job in
such as brass, as it will not feed itself into the the jigs not in fixtures 3–2–1 principle is used to
material more quickly than is desired. locate the job. So only statement 2 is correct.

E
D
A
M
5 Metrology and Inspection
5.1 Match List-I (Measuring Device) with List-II 3. Measurement of gear pitch
Y
(Parameter Measured) and select the correct 4. Joining hydraulic piston rods for agricultural
answer using the codes given below the lists: machinery
List-I 5. Measurement of very small displacements
A. Diffraction grating Codes:
S
B. Optical flat A B C D
C. Auto collimators (a) 5 4 2 1
D. Laser scan micrometer (b) 3 5 1 2
List-II (c) 3 5 4 1
A
1. Small angular deviations on long flat surfaces. (d) 5 4 1 2 [ESE : 1998]
2. Online measurement of moving parts

Answers Metrology and Inspection
E
5.1 (b)
Explanations Metrology and Inspection
5.1 (b)
E
Diffraction grating - Measurement of gear pitch.

Optical flat - Measurement of very small
displacement.
D
Autocollimator - Small angular deviations on long

flat surface.
Laser scan micrometer - Online measurement of
moving part.
A

M
6 NC, CNC, DNC, APT, Automation
6.1 Match List-I (A function connected with NC m/c 6.5 Which of the following pairs are correctly
tool) with List-II (Associated parameter) and matched?
Y
select the correct answer using the codes given 1. CNC machine ... Post processor
below the lists: 2. Machining centre .... Tool magazine
List-I List-II 3. DNC ... FMS
A. Interpolation 1. Tape preparation Select the correct answer using the code given
S
B. Parity check 2. Canned cycle below :
C. Preparatory function 3. Drilling (a) 1, 2 and 3 (b) 1 and 2
D. Point to point control 4. Contouring (c) 1 and 3 (d) 2 and 3
A
5. Turning [ESE : 1996]
Codes:
A B C D 6.6 Assertion (A): Numerically controlled machines
(a) 4 1 2 3 having more than three axes do not exist.
(b) 4 1 2 5
E Reason (R): There are only three cartesian
(c) 5 1 3 2 coordinates namely x-y-z.
(d) 1 4 3 2 [ESE : 1995] (a) both A and R are true and R is the correct
explanation of A
6.2 Consider the following characteristics of
E
production jobs
explanation of A
1. Processing of parts frequently in small lots.
2. Need to accommodate design changes of
products.
D
[ESE : 1996]
3. Low rate of metal removal.
4. Need for holding close tolerances. 6.7 Match List-I (Track numbers on paper tape) with
The characteristics which favour the choice of List-II (Holes on those tracks represent) and select
A
numerically controlled machines would include the correct answer using the codes given below
(a) 1, 2 and 3 (b) 2, 3, and the lists:
(c) 1, 3, and 4 (d) 1, 2, and 4 List-I List-II
[ESE : 1995] A. Track No. 1 to 4 1. Alphabets
M
6.3 In APT language, the cutter motion in incremental B. Track No. 5 2. Numerals
coordinate mode is addressed as C. Track No. 6 & 7 3. End of block
(a) GO/TO/..... (b) GO/TO.... D. Track No. 8 4. Block number
(c) GO DLTA/.... (d) GO FWD/.... 5. Parity check
[ESE : 1995] Codes:
A B C D
6.4 In manual programming and tape preparation for
(a) 2 5 1 3
a NC drilling machine, the spindle speed was
(b) 1 4 2 5
coded as S 684 (using the magic-three code).
(c) 2 4 1 3
The spindle speed in rpm will be
(d) 1 5 2 3
(a) 684 (b) 68.4
[ESE : 1997]
(c) 840 (d) 6840 [ESE : 1996]
6.8 Which of the following are valid statements for Select the correct answer using the codes given
point to point motion of the tool in APT language? below:
1. GO TO/............ (a) 1 and 2 (b) 2 and 3
2. GO DLTA/........ (c) 1 and 3 (d) 1 alone
3. GO/TO,............ [ESE : 1998]
6.11 Transfer machines can be defined as
below:
(a) Material processing machines
(a) 1 and 2 (b) 2 and 3
(b) Material handling machines
(c) 1 and 3 (d) 1, 2 and 3
(c) Material processing and material handling
Y
[ESE : 1997]
machines
6.9 In tape preparation for an NC machine tool the (d) Component feeders for automatic assembly
code S 624 would represent spindle speeds of [ESE : 1999]
S
(a) 624 rpm, 240 rpm and 2346 rpm
6.12 Consider the following statements regarding
(b) 624 rpm and 240 rpm
numerically controlled machine tools
(c) 624 rpm and 246 rpm
1. They reduce non-productive time
(d) 240 rpm and 246 rpm
A
2. They reduce fixturing
[ESE : 1998]
3. They reduce maintenance cost
6.10 Which of the following are the rules of Which of these statements are correct?
programming NC machine tools in APT language? (a) 1, 2, and 3 (b) 1 and 2
1. Only capital letters are used
E (c) 2 and 3 (d) 1 and 3
2. A period is placed at the end of each [ESE : 1999]
statement
3. Insertion of space does not affect the APT
word.
E
Answers NC, CNC, DNC, APT, Automation
6.1 (a) 6.2 (d) 6.3 (c) 6.4 (a) 6.5 (a) 6.6 (b) 6.7 (a) 6.8 (a) 6.9 (d)
D
6.10 (d) 6.11 (c) 6.12 (c)
Explanations NC, CNC, DNC, APT, Automation

A
6.2 (d) Means feed drill 50 mm into work.

GO FWD is an intermediates movement
Numerical control machine has the advantages of: command.
1. Processing of parts frequently in small lots
M
(flexibility of design) 6.5 (a)

2. Reduction in use of jig and fixture. Post processor is a sort of simulation activity in
3. High accuracy and reduced human error. which after programming the execution of tool in
4. Improved productivity. simulated on computer screen.
Machining centre is always associated with tool
6.3 (c) magazine.
GO DLTA/dx,dy,dz
6.8 (a)
This is an incremental instruction used to make
movement of the tool in specified direction from GO/symble for geometric expression is a general
current position. format of contouring motion statements.
Example: Example:
GO DLTA/0, 0, –50 GO/TO, LIN1, TO, CIR 2
Mean tool movement touching the surface of 6.11 (c)

LIN1 onwards touching the counter of CIR 2.
Transfer machines are used to move the
Point to Point Motion: are represented in
workpiece from one station to another in machine
following form:
to enable various operation to be performed on
TO/symbol of geometry
the part. Workpiece are transferred by several
Example:
methods:
GO TO/PT1
1. Rails along which the parts, usually placed
This statement is used to position the cutter
on pallets, are pushed or pulled by various
above required position for example locating
mechanism
drill above hole to be drilled.
Y
2. Rotary indexing tables
GO DLTA/dx, dy, dz
3. Overhead conveyors.
This is an incremental instruction used to make
movement of the tool in specified direction from

current position.
S
A
E
E
D
A
M
7 Non-conventional
Machining Process
7.1 Which one of the following processes does not 7.3 Match List-I with List-II and select the correct
cause tool wear? answer using the codes given below the lists:
Y
(a) Ultrasonic machining List-I
(b) Electrochemical machining A. Die sinking
(c) Electric discharge machining B. Deburring
S
(d) Anode mechanical machining [ESE : 1997] C. Fine hole drilling (thin materials)
D. Cutting/sharpening hard materials
7.2 Match List-I (Machining process) with List-II
(Associated medium) and select the correct List-II
1. Abrasive jet machining
A
List-I List-II 2. Laser beam machining
A. Ultrasonic 1. Kerosene 3. EDM
machining 4. Ultrasonic machining
5. Electrochemical grinding
B. EDM
E
2. Abrasive slurry
C. ECM 3. Vacuum Codes:
D. EBM 4. Salt solution A B C D
Codes: (a) 3 5 4 1
A B C D (b) 2 4 1 3
(a) 2 3 4 1 (c) 3 1 2 5
E
(b) 2 1 4 3 (d) 4 5 1 3 [ESE : 1999]

(c) 4 1 2 3
(d) 4 3 2 1 [ESE : 1998]
D
Answers Non-conventional Machining Process
7.1 (b) 7.2 (b) 7.3 (c)

A
Explanations Non-conventional Machining Process
7.1 (b) 7.3 (c)

M
Electrochemical machining does not cause tool Die sinking – EDM

wear. Deburring – Abrasive jet machine
Tiny hole drilling (thin materials) – Laser beam
7.2 (b) machine
Ultrasonic machining – Abrasive slurry Cutting/Sharpening hard materials –
EOM – Kerosene Electochemical grinding
ECM – Salt solution
EBM – Vacuum
8 Powder Metallurgy
8.1 Which of the following components can be (a) 1, 2, 3, 4 (b) 1, 2, 4, 3
Y
manufactured by powder metallurgy methods? (c) 2, 1, 4, 3 (d) 2, 1, 3, 4
1. Carbide tool tips 2. Bearings [ESE : 1999]
3. Filters 4. brake linings
8.4 Assertion (A): In atomization process of
manufacture of metal powder, the molten metal is
S
below:
forced through a small orifice and broken up by a
(a) 1, 3 and 4 (b) 2 and 3
stream of compressed air.
(c) 1, 2 and 4 (d) 1, 2, 3 and 4
Reason (R): The metallic powder obtained by
[ESE : 1997]
A
atomization process is quite resistant to oxidation.
8.2 In powder metallurgy, the operation carried out to (a) both A and R are true and R is the correct
improve the bearing property of a bush is called explanation of A
(a) Infiltration (b) Impregnation (b) both A and R are true but R is not a correct
(c) Plating
E
(d) Heat treatment explanation of A
[ESE : 1998] (c) A is true but R is false
8.3 Consider the following processes for the
manufacture of gears 8.5 The correct sequence of the given processes in
E
1. Casting manufacturing by powder metallurgy is
2. Powder metallurgy (a) Blending, compacting, sintering and sizing
3. Machining from bar stock (b) Blending, compacting, sizing and sintering
4. Closed die forging (c) Compacting, sizing, blending and sintering
D
The correct sequence in increasing order of (d) Compacting, blending, sizing and sintering
bending strength of gear teeth is [ESE : 1999]

A
Answers Powder Metallurgy
8.1 (d) 8.2 (b) 8.3 (a) 8.4 (c) 8.5 (a)
M
Explanations Powder Metallurgy
8.1 (d) 8.2 (b)

Typical products made by powder-metallurgy Bearings...... Impregnation
technique range from tiny balls for ball-point
pens, to gears, cams, and bushing to cutting 8.3 (a)
tools, to porous products, such as filters and The bending strength of gear will be minimum
oil-impregnated bearing, to a varity of for casting of process and strongest for produced
automotive components such as piston ring, by close die forging.
value guides, connecting rods, and hydraulic
pistons.
8.4 (c) 8.5 (a)

In atomization process, forcing the molten metal Blending → Compacting → Sintering → Sizing.
through a nozzle into a stream of air or nozzle. In Sizing: It consist of placing the sintered part in
the atomization, they usually carry a layer of oxide a die & made to correct dimension & repressing
over them, which means they are more prone to the same to bring it to the required size. It also
the oxidation. takes care of certain distortion which might have
occurred during sintering.

Y
S
A
E
E
D
A
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UNIT
VI
Y
Industrial Engineering
S
and Maintenance Engg.
Syllabus
A
Production planning and Control, Inventory control and operations research - CPM-PERT. Failure concepts and
E
characteristics-Reliability, Failure analysis, Machine Vibration, Data acquisition, Fault Detection, Vibration Monitoring,
Field Balancing of Rotors, Noise Monitoring, Wear and Debris Analysis, Signature Analysis, NDT Techniques in
Condition Monitoring.
E
Contents
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1. Forecasting ...................................................................................................................... 131
2. Inventory, Control and Break Even Analysis..................................................................... 132

A
3. Linear Programming ......................................................................................................... 137
4. PERT and CPM ................................................................................................................ 139

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5. Queuing Theory ................................................................................................................ 141
6. Scheduling, Line Balancing, Product Development, MRP, Process Planning

and Control Plant Layout .................................................................................................. 143
7. Transportation and Assignment ........................................................................................ 147
8. Work Study and Work Measurement ................................................................................ 149
9. Value Engineering ............................................................................................................ 152
10. Element of Computation and Maintenance ....................................................................... 154

1 Forecasting
1.1 Which one of the following methods can be used (a) T and C (b) R and S
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for forecasting the sales potential of a new (c) T, C and S (d) T, C, S and R
product? [ESE : 1997]
(a) Time series analysis
1.3 A company intends to use exponential smoothing
(b) Jury of Executive Opinion method
S
technique for making a forecast for one of its
(c) Sales Force Composite method
products. The previous year’s forecast has been
(d) Direct Survey method
78 units and the actual demand for the
[ESE : 1995]
corresponding period turned out to be 73 units. If
A
1.2 Given the value of the smoothening constant α is 0.2,
T = underlying trend the forecast for the next period will be:
C = cyclic variations within the trend (a) 73 units (b) 75 units
E
S = seasonal variation within the trend and (c) 77 units (d) 78 units
R = residual, remaining or random variation, as [ESE : 1999]
per the time series analysis of sales forecasting,
the demand will be a function of:
Answers Forecasting
E
1.1 (d) 1.2 (d) 1.3 (c)

Explanations Forecasting
D
1.1 (d) 1.3 (c)

Opinion survey method is relatively simple and Fn = αyn–1 + (1 – α)Fn–1
practical method for forcasting demands and = (0.2) (73) + (1 – 0.2) 78 = 14.6 + 62.4
A
especially for new products. = 77
1.2 (d)

As per the time series analysis of sales
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forecasting the demand will be a function of

1. Trend
2. Cyclic fluctuations
3. Seasonal variation
4. Random variation
2 Inventory, Control and
Break Even Analysis
2.1 Consider the following factors: 3. Simulation can be used for inventory control.
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1. Adequate incentive 4. EOQ (Economic Order Quantity) formula
2. Ease of administration ignores variations in demand pattern.
3. Flexibility Which of these statements is/are correct?
4. Guaranteed basic pay (a) 1 only (b) 1 and 3
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5. Higher wages (c) 2, 3 and 4 (d) 1, 2, 3 and 4
6. Simplicity [ESE : 1995]
Among these, the factors which are to be
considered while developing a good wage 2.6 In inventory control theory, the Economic Order
A
incentive plan would include Quantity (EOQ) is
(a) 1, 2, 3 and 5 (b) 2, 3, 4 and 5 (a) average level of inventory
(c) 1, 2, 4 and 6 (d) 1, 2, 5 and 6 (b) optimum lot size
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[ESE : 1995] (c) lot size corresponding to break-even analysis
(d) capacity of a warehouse
2.2 Production cost refers to prime cost plus
[ESE : 1995]
(a) factory overheads
(b) factory and administration overheads 2.7 Given that E = Earnings, R = Rate per hour,
(c) factory, administration and sales overheads T = worked in hours, S = Standard time on the
E
(d) factory, administration and sales overheads basis of date in hours. Rowan wage incentive plan is:
and profit
S −T ⎞
[ESE : 1995] (a) E = RT + ⎛⎜
⎝ S ⎟⎠
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2.3 For a small scale industry, the fixed cost per

month is Rs. 5000/-. The variable cost per product (b) E = RT + (S – T)R
is Rs. 20/- and sales price is Rs. 30/- per piece. (c) E = RT + 0.4 (S – T)R
The break-even production per month will be
A
⎛ S −T ⎞
(a) 300 (b) 460 (d) E = RT + ⎜ RT
⎝ S ⎟⎠
(c) 500 (d) 10000
[ESE : 1995] [ESE : 1996]
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2.4 Classifying items in A, B and C categories for 2.8 Given that, θ = procurement cost per order,
selective control in inventory management is done D = number of units demanded per year,
by arranging items in the decreasing order of
H = holding cost per unit year, i = rate of interest,
(a) total inventory costs
p = purchase price per unit. The procurement
(b) item value
quantity per order (Q) is given by
(c) annual usage value
(d) item demand 2.θ.D 2.θ.D
(a) Q = (b) Q =
[ESE : 1995] H + iP iH + P

2.θ.D 2.θ
1. ABC analysis is based on Pareto’s principle. (c) Q = (d) Q =
H + iP D(H + iP)
2. FIFO and LIFO policies can be used for
material valuation in materials management. [ESE : 1996]
Industrial Engineering and Maintenance Engineering 133
2.9 Two alternative methods can produce a product (a) Rs. 75 (b) Rs. 87
first method has a fixed cost of Rs. 2000/- and (c) Rs. 57 (d) Rs. 55
variable cost of Rs. 20/- piece. The second method [ESE : 1997]
has fixed cost of Rs. 1500/- and a variable cost
2.12 Process I requires 20 units of fixed cost and
of Rs. 30/-. The break even quantity between the
3 units of variable costs per piece, while
two alternatives is:
process II required 50 units of fixed costs and
(a) 25 (b) 50
1 unit of variable cost per piece. For a company
(c) 75 (d) 100 producing 10 pieces per day:
[ESE : 1996] (a) Process I should be chosen
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2.10 Consider the data given in the following table: (b) Process II should be chosen
(c) Either of the two processes should be chosen
Production Plan (d) A combination of the process I and process
Period Demand Regular Overtime Others II should be chosen
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Prod. Prod. [ESE : 1997]
1 500 500 –– –– 2.13 Annual demand for a product costing Rs. 100
2 650 650 –– –– per piece is 900. Ordering cost per order is
A
3 800 650 150 –– Rs. 100 and inventory holding cost is Rs. 2 per
4 900 650 150 ? unit per year. The economic lot size is
(a) 200 (b) 300
Give the fact that production in regular and
(c) 400 (d) 500
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overtime is limited to 650 and 150 respectively,
[ESE : 1997]
the balance demand of 100 units in the 4th period
can be met by: 2.14 Based on the given graph, the economic range
(a) Using overtime in period 2 of batch sizes to be preferred for general purpose
(b) Using regular production in period 1 machine (GP), NC machine (NC) and special
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(c) Subcontracting purpose (SP) will be:
(d) Using any of the steps indicated in (A), (B) GP NC
and (C) SP
D
[ESE : 1997]
Manufacturing
2.11 M/s. ABC and Co. is planning to use the most

1 4
cost
competitive manufacturing process to produce an

A
2
ultramodern sports shoe. They can use a fully
automatic robot-controlled plant with an 3 5
investment of Rs. 100 million; alternately they can

go in for a cellular manufacturing that has a fixed Batch Size
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cost of Rs. 80 million. There is yet another choice Codes:

GP NC SP
of traditional manufacture that needs an
A. 2 5 4
investment of Rs. 75 million only. The fully
B. 1 4 5
automatic plant can turn out a shoe at a unit
C. 3 2 4
variable cost of Rs. 25 per unit, whereas the cellular
D. 1 4 2
and the job shop layout would lead to a variable
[ESE : 1997]
cost of Rs. 40 and Rs. 50 respectively. The break
even analysis shows that the break even quantities 2.15 Details of cost for make or buy decision are shown
using automatic plant Vs. traditional plant are in in the below graph. A discount is offered for
the ratio of 1 : 2. The per unit revenue used in the volume of purchase above ‘V’. Which one of the
break even calculation is: following ranges would lead to the economic
decision?
Period Planned Week-1 Week-2 Week-3

Planned Production 50 100 100
BUY a
Week-4 Week-5 Week-6
BUY b
100 150 50
COST
Each product requires a purchased component
MAKE A in its sub-assembly. Before the start of week-1,
there are 400 components of type A in stock. The
lead time to procure this component is 2 weeks
1 2 3 4
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O and the order quantity is 400. Number of
V
components A per product is only one. The
VOLUME REQUIRED
manufacturer should place the order for:
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(a) 400 components in week-1
(b) 400 components in week-3
Buy a , b Make
(c) 200 components in week-1 and 200
(a) 1 and 2 3 and 4
A
components in week-3
(b) 1 and 3 2 and 4
(d) 400 components in week-5 [ESE : 1999]
(c) 2 and 4 1 and 3
(d) 1 and 4 2 and 3 [ESE : 1998] 2.18 A dealer sells a radio set at Rs. 900 and makes
2.16 Which of the following cost elements are
E 80% profit on his investment. If he can sell it at
considered while determining the Economic Lot Rs. 200 more, his profit as percentage of
Size for purchase? investment will be:
1. Inventory carrying cost (a) 160 (b) 180
2. Procurement cost (c) 100 (d) 120 [ESE : 1999]
E
3. Set up cost 2.19 Consider the following costs:

Select the correct answer using the codes given 1. Cost of inspection and return of goods
below: 2. Cost of obsolescence
D
(a) 1, 2 and 3 (b) 1 and 2 3. Cost of scrap

(c) 2 and 3 (d) 1 and 3 [ESE : 1998] 4. Cost of insurance
2.17 A manufacturer’s master product schedule of 5. Cost of negotiation with suppliers
A
product is given below: Which of these costs are related to inventory

carrying cost?
(a) 1, 2 and 3 (b) 1, 3 and 4
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(c) 2, 3 and 4 (d) 2, 4 and 5

[ESE : 1999]

Answers Inventory, Control and Break Even Analysis
2.1 (c) 2.2 (a) 2.3 (c) 2.4 (c) 2.5 (d) 2.6 (b) 2.7 (d) 2.8 (c) 2.9 (b)
2.10 (b) 2.11 (*) 2.12 (a) 2.13 (b) 2.14 (b) 2.15 (a) 2.16 (b) 2.17 (b) 2.18 (d)
2.19 (c)
Explanations Inventory, Control and Break Even Analysis
2.1 (c) order which minimizes total annual cost of

carrying inventory and cost of ordering under the
Good wage incentive plans have
assumed conditions of certainty and that annual
1. Adequate incentive
demands.
2. Ease of administration
3. Guaranteed basic pay 2.7 (d)
4. Simplicity
In Rowan plan wage of a worker is given by:
2.2 (a)
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⎛ S −T ⎞
E = RT + ⎜ RT
Prime cost = Direct material cost + Direct labour ⎝ S ⎟⎠
cost + direct expenses
2.8 (c)
Production cost = Prime cost + factory overhead
S
Procurement quantity per order will be the EOQ =
2.3 (c) 2θD
CF + CVx = Cpx H + ip
∴ x=
(CP
CF
− CV )
A 2.9 (b)
2000 + 20x = 1500 + 30x
5000 5000
E 30x – 20x = 2000 – 1500
= = = 500 10 x = 500
(30 − 20) 10
∴ x = 50
where
CF = fixed cost 2.10 (b)
E
Variable cost In the 4th period since regular production is
CV = limited to 650 and overtime is limited to 150, the
Product
balance demand of 100 units in the 4th period
Sales cost
CP = can be met by using regular production in
D
Product
period 1.
2.4 (c)
∵ Demand is only 500 but production capacity
in regular period can be increased to 600 to meet
A
the demand.
90
2.11 ( *)
80
Percentage Value
70 Let the sale cos t be Cs

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60 Let break even quantity for fully automatic plant is

50 ‘x’ & break even quantity, for traditional plant is ‘y’.
40 100 × 106 + 25 x = Cs x ...(i)
30 A B C
75 × 10 6 + 50 y = Cs y ....(ii)
20
x 1
10 ∵ =
y 2
0 10 20 30 40 50 or y = 2x
Percentage units Dividing equation (i) by (ii)
100 × 106 + 25x x
2.6 (b) or
6
= (since y = 2x)
75 × 10 + 50(2x) 2x
Economic Order Quantity (EOQ) is that size of
or {(100 × 106)+ 25x} 2 = 75 × 106 × 100x 2.17 (b)

or 200 × 106 + 50x = 75 × 106 + 100x
Week
or 50x = 125 × 106 Order quantity=400
Lead time = 2 week
1 2 3 4 5 6
∴ x = 25 × 105 Planned Production 100
50 100 100 150 50
(Cs – 25) × 25 × 105 = 100 × 106 Receipts 400
Cs – 25 = 40 Avaialbe on
hands 400 350 250 150 50 300 250
∴ Cs = 40 + 25 = 65 Planned order 400
Release
2.12 (a)
The manufacture should place the order for 400
For process I: CF + CVx = 20 + 3 × 10=50
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component in week-3.
Process II: CF + CVx = 50 + 1 × 10 = 60
∵ Total cost for process I is less than II 2.18 (d)
∴ Process I is chosen C.P. × Profit
S
S.P. = C.P. +
2.13 (b) 100
A = Annual consumption in rupees 900 × (100)

C.P = = 500
C0 = Cost of placing an order (100 + 80)
A
i = Inventory carring cost per unit per year S.P if he sells at 200 more = 900 + 200 = 1100
2 × A × C0 1100 − 500
EOQ = = 2 × 900 × 100 = 300 ∴ Profit (in %) = × 100 = 120%
i 500
2
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2.16 (b) 2.19 (c)
Following cost elements are considered while Inventory carrying costs are:
determining the economic lot size (i) Invested capital cost
1. Inventory carrying cost (ii) Record keeping and administrative cost
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2. Ordering cost or procurement cost (iii) Handling cost

The set up cost does not comes into play while (iv) Storage cost
purchasing. (v) Depreciation, Deterioration and obsolescence
D
cost
(vi) Purchase price or production costs
(vii) Taxes and insurance costs

A
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3 Linear Programming
3.1 Which one of the following subroutines does a (c) Artificial variable
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computer implementations linear programming by (d) Basis [ESE : 1998]
the simplex method use?
3.4 In the solution of a linear programming problem
(a) Finding a root of a polynomial
by simplex method, if during an iteration, all ratios
(b) Finding the determinant of a matrix
of right-hand side bi to the coefficients of entering
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(c) Finding the Eigen values of a matrix
variable a are found to be negative, it implies that
(d) Solving a system of linear equations
the problem has:
[ESE : 1996]
(a) Infinite number of solutions
A
3.2 Consider the following linear programming (b) Infeasible solution
problem: (c) Degeneracy
Max. Z = 2A + 3B, subject to A + B < 10, 4A + (d) Unbound solution [ESE : 1999]
6B < 30, 2A + B < 17, A, B > 0
E 3.5 Consider the following statements regarding the
What can one say about the solution? characteristics of the standard form of a linear
(a) It may contain alternative optima programming problem:
(b) The solution will be unbounded 1. All the constraints are expressed in the form
(c) The solution will be degenerate of equations.
(d) It cannot be solved by simplex method
E
2. The right-hand side of each constraint
[ESE : 1997]
equation is non-negative.
3.3 A variable which has no physical meaning, but is 3. All the decision variables are non-negative.
used to obtain an initial basic feasible solution to Which of these statements are correct?
D
the linear programming problem is referred to as: (a) 1, 2 and 3 (b) 1 and 2
(a) Basic variable (c) 2 and 3 (d) 1 and 3 [ESE : 1999]
(b) Non-basic variable

A
Answers Linear Programming
3.1 (d) 3.2 (a) 3.3 (c) 3.4 (d) 3.5 (a)
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Explanations Linear Programming
3.1 (d) A B
2A + B ≤ 17 + ≤1
Simplex method is used to solve a system of linear 8.5 17
A, B ≥ 0
equations.
3.2 (a) 2A + B = 17
A + B = 10
Z = 2A + 3B
A B
A + B ≤ 10 + ≤1 4A
10 10 +6
B
A B =3
4A + 6B ≤ 30 + ≤1 0
7.5 5
Z(7.5,0) = 15
Z(0,5) = 15
Maximum value of objective function = 15 3.5 (a)

and it has alternative optimal solutions because
Characteristics of the standard form of a LPP.
of same constraint as objective function.
1. All the constraints are expressed in the form
3.3 (c) of equations.
2. The RHS of each constraint equation is non-
Artificial variable is used to obtain on initial basic
negative.
feasible solution to the linear programming
3. All the decision variables are non-negative.
problem.

3.4 (d)
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All ratio of right hand side to the coefficients of
entering variable are found to be negative. It
implies that the problem has unbounded solution.
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A
E
E
D
A
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4 PERT and CPM
4.1 Which of the following are the guidelines for the (a) zero (b) 34%
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construction of a network diagram? (c) 50% (d) 84% [ESE : 1997]
1. Each activity is represented by one and only
4.5 The variance (V1) for critical path
one arrow in the network
2. Two activities can be identified by the same a → b = 4 time units, b → c = 16 time units,
c → d = 4 time units, d → e = 1 time unit.
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beginning and end events
3. Dangling must be avoided in a network The standard deviation of the critical path a → e
diagram is:
4. Dummy activity consumes no time or resource (a) 3 (b) 4
A
Select the correct answer the codes given below: (c) 5 (d) 6 [ESE : 1997]
(a) 1, 2 and 3 (b) 1, 3 and 4
4.6 Estimated time TC and variance of the activities
(c) 1, 2 and 4 (d) 2, 3 and 4
‘V’ on the critical path in a PERT network are given
[ESE : 1996]
E
in the following table:
4.2 In the network shown below the critical path is
along: Activity TC (days) V (days)
5 a 17 4
3
4 5 b 15 4
E
3 4 g 8 1
1 2 D1 D2 8 9
The probability of completing the project in 43 days
2 6
is:
D
5 6 7
3 4 (a) 15.6% (b) 50.0%
(a) 1–2–3–4–8–9 (b) 1–2–3–5–6–7–8–9 (c) 81.4% (d) 90.0% [ESE : 1998]
(c) 1–2–3–4–7–8–9 (d) 1–2–5–6–7–8–9
4.7 The earliest occurrence time for event ‘1’ is 8
A
[ESE : 1996]
weeks and the latest occurrence time for event
4.3 Assertion (A): Generally PERT is preferred over
CPM for the purpose of project evaluation. ‘1’ is 26 weeks. The earliest occurrence time for
Reason (R): PERT is based on the approach of event ‘2’ is 32 weeks and the latest occurrence
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multiple time estimates for each activity. time for event ‘2’ is 37 weeks. If the activity time
(a) both A and R are true and R is the correct is 11 weeks, then the total float will be:
explanation of A (a) 11 (b) 13
(b) both A and R are true but R is not a correct (c) 18 (d) 24 [ESE : 1998]
explanation of A
4.8 Time estimates of an activity in a PERT network
are:
Optimistic time t0 = 9 days; pessimistic time
4.4 In a PERT network, expected project duration is tp = 21 days and most likely time tm = 15 days.
found to be 36 days from the start of the project. The approximates probability of completion of this
The variance is four days. The probability that activity in 13 days is:
the project will be completed in 36 days is: (a) 16% (b) 34%
(c) 50% (d) 84% [ESE : 1999]

Answers PERT and CPM
4.1 (b) 4.2 (b) 4.3 (a) 4.4 (c) 4.5 (c) 4.6 (c) 4.7 (c) 4.8 (a)
Explanations PERT and CPM

4.1 (b) of projects. These are the Critical Path Method
(CPM) and the project evaluation and Review
Rules for drawing Network Diagram:
(i) Each activity is represented by one and only Technique (PERT).
one arrow in the network. CPM – Activity Oriented
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(ii) No two activity can be identified by the PERT – Event Oriented
same end events. 4.4 (c)
(iii) In order to ensure the correct precedence Standard deviation (s.d):
relationship in the arrow diagram, following
var = 4 =2
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question must be checked whenever any
activity is added to network. X − X 36 − 36
Z= = =0
(a) What activity must be completed σ 2
P(0) = 0.5
A
immediately before this activity can
start? ∴ the probability that the project will be completed
(b) What activity must follow this activity? in 36 days is 50%
(c) What activity must occur simultaneously
4.5 (c)
with this activity?
E
4.2 (b) Standard deviation of critical path a → e is
7 7 12 15 = 4 + 16 + 4 + 1 = 25 = 5
5
3 4 5 20 20 24 24 4.6 (c)
4 4
E
8 9
1
3 D1 D2 S.d = 4 + 4 + 1= 3
2
0 0 3 3
6 X − X 43 − 40
2 Z= = =1
5
3
6 4
7 σ 3
D
10 10 14 14 P(1) = 0.8413
7 7
4.7 (c)
TF = LST = EST
Ei Ej Li Lj
A
Activities Duration EST LST EFT LFT Total Remark

Float 8 32 26 37
1− 2 3 0 0 3 0
2−3 4 3 3 7 0 Total float = (Lj– Ei) – dij
3−4 5 7 10 15 3
∵ Lj = 37
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2−5 2 3 5 7 2
4−8 5 12 15 20 3 Ei = 8
5−6 3 7 7 10 0
6−7 4 10 10 14 0 dij = 11
7−8 6 14 14 20 0
T.F = 37 – 8 – 11 = 18
8−9 4 20 20 24 0
4−7 0 12 14 14 2
3−5 0 7 7 7 0
4.8 (a)
Therefore critical path t0 + 4tm + tp 9 + (4 × 15) + 21
te xpected = = = 15
1–2–3–4–5–6–7–8–9 6 6
and total project duration (b − a) 21 − 9
= 3 + 4 + 3 + 4 + 6 + 4 = 24 S.D = = =2
6 6
x − x 13 − 15
4.3 (a) Z= = = −1
σ 2
Project management has evolved two analytical p(–1) = 0.1586 0.16
technique for planning, scheduling and controlling

5 Queuing Theory
5.1 Assertion (A): In a queueing model, the 5.4 In a single server queue customers are served at
Y
assumption of exponential distribution with only a rate of µ. If W and Wq represent the mean waiting
one parameter family for service times is found time in the system and mean waiting time in the
to be unduly restrictive. queue respectively, then W will be equal to
R e a s o n ( R ) : This is partly because the (a) Wq – µ (b) Wq + µ
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exponential distribution has the property that (c) Wq + 1/µ (d) Wq – 1/µ
smaller service times are inherently less probable [ESE : 1997]
than large service time.
5.5 For a M/M/1 : ∞/FCFS queue, the mean arrival
A
rate is equal to 10 per hour and the mean service
explanation of A
rate is 15 per hour. The expected queue length is
(a) 1.33 (b) 1.53
explanation of A
E (c) 2.75 (d) 3.20
[ESE : 1998]
5.6 An operations consultant for an automatic car wash
5.2 If the arrival rate of units is l and the service rate
wishes to plan for enough capacity to handle
is µ for a waiting line system having ‘m’ number 60 cars per hour. Each car will have wash time to
E
of service stations, then the probability of a 2 minutes, but there is to be a 20% allowance for
service unit being turned out in time interval setup, delays and payment transactions. The
(t, t + Δt) is installation capacity of car wash stalls should be:
D
(a) Zero (b) μ.Δt (a) 3 (b) 4

(c) m.μ.Δt (d) n.μ.Δt (c) 5 (d) 6 [ESE : 1999]
[ESE : 1996]
5.7 The average time between two arrivals of
A
5.3 Consider two queueing disciplines in a single customers at a counter in a ready-made garment
server queue. Case 1 has a first come first served store is 4 min. The average time of the counter
discipline and case 2 has a last come first served clerk to serve the customer is 3 min. The arrivals
discipline. If the average waiting times in the two are distributed as per Poisson distribution and
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cases are W1 and W2 respectively, then which the services are as per the exponential
one of the following inferences would be true? distribution. The probability that a customer
(a) W1 > W2 arriving at the counter will have to wait, is:
(b) W1 < W2 (a) Zero (b) 0.25
(c) W1 = W2 (c) 0.50 (d) 0.75 [ESE : 1999]
(d) Data insufficient to draw any tangible

inference [ESE : 1997]
Answers Queuing Theory
5.1 (c) 5.2 (a) 5.3 (c) 5.4 (c) 5.5 (a) 5.6 (a) 5.7 (d)
Explanations Queuing Theory

5.3 (c) Length of queue
Average waiting time in the system in both the
2
cases will be ⎛ 2⎞ 4
ρ2 ⎜⎝ ⎟⎠
3
µ = Service rate; Lq = = = 9 = 1.33
λ = Arrival rate 1− ρ 2 1
1−
3 3
1
Wq =
(µ − λ)
5.6 (a)
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5.4 (c) Time required to wash one car is
2 × 1.2 = 2.4 mins. Number of cars washed in
LS 1⎛ ρ ⎞
W= = ⎜ 1 hr in 1 stall
λ ⎝ 1 − ρ⎠⎟
S
λ
60
= = 25
Lq 1⎛ ρ ⎞ 2 2.4
=
λ ⎜⎝ 1 − ρ ⎟⎠
Wq =
A
λ
60
∴ Number of stalls = = 2.4 3
25
Ls Lq + ρ Lq ρ
∵ W= = = +
λ λ λ λ
E 5.7 (d)
Lq λ Lq 1 60
= + = + λ = Number of arrivals/hour = = 15
λ μ×λ λ μ 4
μ = Number of customers serviced/hour
1
E
= Wq +
μ =
60
= 20
3
5.5 (a) Probability that customer will have to wait
D
λ = 10 (Arrival rate); μ = 15 (Service rate) 15

= = 0.75
10 2 20
ρ = =
15 3
A
M
Scheduling, Line Balancing, Product
6 Development, MRP, Process Planning
and Control Plant Layout
Y
6.1 Which of the following charts are used for plant Reason (R): The work to be performed on the
layout design? product is the determining factor in the positioning
1. Operation process chart of the manufacturing equipment in product layout.
S
2. Man machine chart (a) both A and R are true and R is the correct
3. Correlation chart explanation of A
4. Travel chart (b) both A and R are true but R is not a correct
A
Select the correct answer using the codes given explanation of A
below: (c) A is true but R is false
(a) 1, 2, 3 and 4 (b) 1, 2 and 4 (d) A is false but R is true [ESE : 1995]
(c) 1, 3 and 4 (d) 2 and 3
E
[ESE : 1995]
6.6 Which of the following are the principles of material
handling?
6.2 In manufacturing management, the term 1. Keep all handling to the minimum.
“Dispatching” is used to describe 2. Move as few pieces as possible in one unit.
(a) dispatch of sales order 3. Move the heaviest weight to the least
(b) dispatch of factory mail
E
distance.
(c) dispatch of finished product to the user
4. Select only efficient handling equipment.
(d) dispatch of work orders through shop floor
[ESE : 1995]
below:
D
6.3 Which of the following factors are to be considered (a) 1, 2, 3 and 4 (b) 1, 3 and 4
for production scheduling? (c) 1, 2 and 3 (d) 2 and 4
1. Sales forecast 2. Component design [ESE : 1996]
A
3. Route Sheet 4. Time standards

6.7 Consider the following aspects:
1. Speed 2. Decision making
below:
3. Accuracy 4. Cost savings
Codes:
M
Use of computers hold substantial advantages

(a) 1, 2 and 3 (b) 1, 2 and 4
over manual methods in the case of
(c) 1, 3 and 4 (d) 2, 3 and 4
(a) 1, 2 and 3 (b) 2 and 4
[ESE : 1995]
(c) 1, 3 and 4 (d) 1, 2, 3 and 4
6.4 A device for lifting or lowering objects suspended [ESE : 1996]
from a hook at the end of a retractable chain or
6.8 The routing function in a production system design
cable is called
is concerned with:
(a) hoist (b) jib crane
(a) Manpower utilization
(c) chain conveyor (d) elevator
(b) Machine unitization
[ESE : 1995]
(c) Quality assurance of the product
6.5 Assertion (A): Product layout is more amenable (d) Optimizing material flow through the plan
to automation than process layout. [ESE : 1996]
6.9 Match List-I (Type of Products) with List-II (Type 6.12 There are two machines M1 and M2 which process
of layout) and select the correct answer using the jobs A , B , C , D , E and F . The processing
codes given below the lists: sequence for these jobs is M1 followed by M2.
List-I Consider the following data in this regard:
A. Ball bearings Process time required in minutes
B. Tools and gauges Jobs A B C D E F
C. Large boilers M1 4 7 3 12 11 9
D. Motor cycle assembly M2 11 7 10 8 10 13
List-II
The processing sequence of jobs that would
Y
1. Process layout
minimize the make span is:
2. Product layout
(a) C-A-B-F-E-D (b) C-A-B-D-E-F
3. Combination of product and process layout
(c) C-A-D-B-F-E (d) E-F-D-B-A-C
4. Fixed position layout
S
[ESE : 1997]
Codes:
6.13 Match List-I (Methods) with List-II (Problems) and
A B C D
select the correct answer using the codes given
(a) 1 3 4 2
A
below the lists:
(b) 3 1 4 2
(c) 1 2 4 3 List-I
(d) 3 1 2 4 [ESE : 1996] A. Moving average
B. Line balancing
E
6.10 Consider the following sets of tasks to complete C. Economic batch size
the assembly of an engineering component: D. Johnson algorithm
Task Time (in seconds) Precedence List-II
1. Assembly
a 10 ––
2. Purchase
E
b 20 ––
3. Forecasting
c 15 a
4. Sequencing
d 5 b
Codes:
D
e 30 c
A B C D
f 15 e
(a) 1 3 2 4
g 5 d
(b) 1 3 4 2
A
The expected production rate is 3000 units per (c) 3 1 4 2

shift of 8 hour duration. The minimal number (d) 3 1 2 4 [ESE : 1998]
workstations that are needed to achieve this 6.14 Consider the following statements:
production level is: Dispatching
M
(a) 4 (b) 8 1. Is the action of operations, planning and control

(c) 10 (d) 11 [ESE : 1997]
2. Releases work to the operating divisions.
6.11 A production line is said to be balanced when 3. Conveys instructions to the shop floor
(a) there are equal number of machines at each Which of these statements are correct?
work station (a) 1, 2 and 3 (b) 1 and 2
(b) there are equal number of operators at each (c) 2 and 3 (d) 1 and 3
work station [ESE : 1998]
(c) the waiting time for service at each station is 6.15 Which of the following are the benefits of
the same assembly line balancing?
(d) the operation time at each station is the same 1. It minimizes the in-process inventory.
[ESE : 1997] 2. It reduces the work content.
3. It smoothens the production flow. 6.18 Which of the following correctly explains process
4. It maintains the required rate of output. capability?
Select the correct answer using the codes given (a) Maximum capacity of the machine
below: (b) Mean value of the measured variable
(a) 1, 2 and 3 (b) 2, 3 and 4 (c) Lead time of the process
(c) 1, 3 and 4 (d) 1, 2 and 4 (d) Maximum deviation of the measured variables
[ESE : 1998] of the components [ESE : 1998]
6.16 The characteristic life-cycle of a product consists 6.19 Which one of the following statements is correct
of four periods. The rate of consumption increases in relation to production, planning and control?
Y
rapidly at the beginning of the: (a) Expediting initiates the execution of
(a) Incubation period (b) Growth period production plans, whereas despatching
(c) Maturity period (d) Decline period maintains them and sees them through to their
[ESE : 1998] successful completion
S
(b) Despatching initiates the execution of
6.17 Which of the following input data are needed for
production plans, whereas expediting
MRP?
maintains them and sees them through to their
1. Master production schedule
A
successful completion
2. Inventory position
(c) Both despatching and expediting initiate the
3. Machine capacity
execution of production plans
4. Bill of materials
(d) Both despatching and expediting maintain the
E
production plans and see them through to
below:
their successful completion [ESE : 1999]
(a) 1, 2 and 3 (b) 2, 3 and 4
(c) 1, 2 and 4 (d) 1, 3 and 4
[ESE : 1998]
E
Answers Scheduling, Line Balancing, Product Development, MRP, Process Planning and Control Plant Layout
6.1 (b) 6.2 (d) 6.3 (d) 6.4 (a) 6.5 (a) 6.6 (b) 6.7 (b) 6.8 (d) 6.9 (c)
D
6.10 (a) 6.11 (d) 6.12 (a) 6.13 (d) 6.14 (a) 6.15 (c) 6.16 (b) 6.17 (c) 6.18 (d)
6.19 (b)
Explanations Scheduling, Line Balancing, Product Development, MRP, Process Planning and Control Plant Layout
A
6.1 (b) 6.3 (d)

Tools and techniques of plant layout Factors considered for product scheduling.
M
1. Process charts (operation and flow) 1. Component design

2. Travel chart 2. Route sheet
3. Diagram (flow diagram, string diagrams) 3. Time standards
4. REL (relationship chart)
5. Templates 6.4 (a)
6. Scaled models • Conveyors primarily perform the movement
of uniform loads between fixed points.
6.2 (d) • Cranes are overhead devices capable of
Dispatching basically is the physical delivery of moving materials vertically and laterally in
orders and instructions to all the persons who area of limited length and width and height.
are involved in actual production and other • Hoists are used for loading and unloading of
supporting activities. heavy objects and they are also used for
raising and lowering heavy and long objects.
6.6 (b) production orders are ready, it is the responsibility

of the dispatching section to trigger the flow of
Principle of material handling:
information and instructions, the issue of
1. Keep all handling to the minimum
materials, issue of tools and production aids etc.
2. Move the heaviest weight to the least distance.
to all the concerned personnel. Dispatching are
3. Select only efficient handling equipment. nothing but the internal courier in an industry.
4. Increase quantity, size, weight of load handled.
6.15 (c)
6.9 (c)
Advantages of assembly line balancing
It is difficult to move large boilers from point hence
1. It minimizes the in-process inventory.
it has fixed position layout. Assembly work always
Y
2. It smoothens the production flow.
has product layout. Tools and gauges are not mass
3. Itt maintains the required rate of output.
manufactured and need a lot of variations, process
layout is used. For ball bearing a combination of 6.16 (b)
S
product and process layout is used.
6.10 (a) III
Total work content IV
nmin = II
Cycle time
A
Sales volume
Where total work content, and profit
I
= 10 + 20 + 15 + 5 + 30 + 15 + 5 Sales volume
= 100
Profit
Time = Largest station time
E
100
∴ nmin = = 3.3 ≈ 4 Time
30 I. Introduction stage
II. Growth stage rate of consumption increases
6.11 (d)
rapidly.
E
A production line is said to be balanced when the III. Maturity stage
operation time at each station is the same. IV
IV.. Declining stage
6.12 (a) 6.17 (c)
D
Examine the column for processing time on

The inputs to the MRP system are:
machine M1 and M2 and find the smallest value
(i) Master production schedule
[min (M1, M2)] and allocate on extreme side if M2
(ii) Inventory status file
is smallest otherwise on extreme left side in
A
sequence. (iii) Bill of materials (BOM)

M1 M2
6.18 (d)
C A B F E D
Process capability study is carried out to measure
M
6.13 (d) the ability of the process to meet the specified

Moving average Forecasting tolerances. It may be defined as the minimum spread
Line balancing Assembly of a specific measurement variation which will include
Economic batch size Purchase 99.7% of the measurement from the given process.
Johnson algorithm Sequencing 6.19 (b)
Dispatching executes planning function and
6.14 (a)
insures that the plans are properly implemented.
Dispatching basically is the physical delivery of
It is concerned with getting the work started.
orders and instructions to all the persons who
are involved in actual production and other Expediting takes action if the progress reporting
supporting activities when schedule plan and indicates a deviation of the plan from the originally
set targets.

7 Transportation and
Assignment
7.1 Match L i s t - I (OR technique) with L i s t - I I Reason (R): VAM heuristic gives an approximate
Y
(Application) and select the correct answer using solution. It is checked for optimality test. If it is
the codes given below the lists: optimal, the algorithm stops there. If it is not an
List-I optimal solution, then improved solutions are
A. Linear programming found out through very few iterations till optimality
S
B. Transportation is reached.
C. Assignment (a) both A and R are true and R is the correct
D. Queueing explanation of A
List-II (b) both A and R are true but R is not a correct
A
1. Warehouse location decision explanation of A
2. Machine allocation decision (c) A is true but R is false
3. Product mix decision (d) A is false but R is true [ESE : 1996]
4. Project management decision
E 7.5 When there are ‘m’ rows and ‘n’ columns in a
5. Number of servers decision
transportation problem, degeneracy is said to
Codes:
occur when the number of allocations is
A B C D
(a) Less than (m + n – 1)
(a) 1 2 3 5
(b) Greater than (m + n –1)
E
(b) 3 1 2 5
(c) Equal to (m – n – 1)
(c) 1 3 4 5
(d) less than (m – n – 1) [ESE : 1997]
(d) 3 2 1 4 [ESE : 1995]
7.6 Match List-I (Methods) with List-II (Applications)
D
7.2 The solution in a transportation model (of

and select the correct answer using the codes
dimension m x n) is said to be degenerate if it
given below the lists:
has List-I
(a) exactly (m + n – 1) allocations A. Break even analysis
A
(b) fewer than (m + n – 1) allocations B. Transportation problem

(c) more than (m + n – 1) allocations C. Assignment problem
(d) (m × n) allocations [ESE : 1995] D. Decision tree
M
7.3 A solution is not a basic feasible solution in a List-II

transportation problem if after allocations: 1. To provide different facility at different locations
(a) There is no closed loop 2. To take action from among the paths with
(b) There is a closed loop uncertainty
(c) Total number of allocations is one less than 3. To choose between different methods of
the sum of number of sources and manufacture
destinations 4. To determine the location of the additional plant
(d) There is degeneracy Codes:
[ESE : 1996] A B C D
(a) 4 3 1 2
7.4 Asser tion (A): Transportation problem can be
Assertion
(b) 3 4 1 2
solved by VAM heuristic much faster as compared
(c) 3 4 2 1
to the solution through linear programming method.
(d) 4 3 2 1 [ESE : 1998]
7.7 In a transportation problem, the materials are Select the correct answer using the codes given
transported from 3 plants to 5 warehouses. The below:
basic feasible solution must contain exactly, which (a) 1, 2 and 3 (b) 1 and 3
one of the following allocated cells? (c) 2 and 3 (d) 1 and 2
(a) 3 (b) 5 [ESE : 1998]
(c) 7 (d) 8 [ESE : 1998]
7.9 In a transportation problem North-West corner rule
7.8 The assignment algorithm is applicable to which would yield:
of the following combined situations for the (a) An optimum solution
purpose of improving productivity? (b) An initial feasible solution
Y
1. Identification of the sales force-market. (c) A Vogel’s approximate solution
2. Scheduling of operator-machine. (d) A minimum cost solution [ESE : 1999]
3. Fixing machine-location
S
Answers Transportation and Assignment
7.1 (b) 7.2 (b) 7.3 (b) 7.4 (a) 7.5 (a) 7.6 (b) 7.7 (c) 7.8 (c) 7.9 (b)
Explanations Transportation and Assignment
7.1 (b)
Linear programming Product mix decision

A 7.5 (a)
Degeneracy arises when number of allocation is
Transportation Warehouse location

E less than m + n – 1
decision 7.6 (b)

Assignment Machine allocation (a) Break even analysis: To choose between
decision different methods of manufacture
E
Queueing Number of servers (b) Transportation problem: To determine the
decision location of the additional plant
(c) Assignment problem: To provide different
7.2 (b) facility at different locations.
D
(d) Decision tree: To take action from among the

In a TP, if the number of non-negative
paths with uncertainty
independent allocations is less than m + n – 1,
there exists a degeneracy. 7.7 (c)
A
7.3 (b) Degeneracy arises when number of allocation are

less than 3 + 5 – 1 = 7
A basic feasible solution will contain m + n –1
independent non-zero allocations and the 7.9 (b)
M
indication of independence of a set of individual

The solution of a transportation problem can be
positive allocations is that we can’t form a closed
obtained in two stages namely initial solution and
loop by joining positive allocations by horizontal
optimum solution. Initial solution can be obtained
and vertical lines only.
by using one of the three methods:
7.4 (a) (i) North west corner rule
(ii) Least cost method
VAM gives an approximate solution which can be
(iii) Vogel’s approximation method (VAM)
optimal. If not optimal then very few iterations are
required till optimality is reached.
8 Work Study and Work
Measurement
8.1 In time study, the rating factor is applied to (d) Analysis of standard date system
Y
determine [ESE : 1996]
(a) standard time of a job
8.5 Procedure of modifying work content to given
(b) merit rating of the worker
more meaning and enjoyment to the job by
(c) fixation of incentive rate
involving employees in planning, organization and
S
(d) normal time of job [ESE : 1995]
control of their work, is termed as:
8.2 Work study is mainly aimed at (a) Job enlargement (b) Job enrichment
(a) determining the most efficient method of (c) Job rotation (d) Job evaluation
A
performing a job [ESE : 1996]
(b) establishing the minimum time of completion
8.6 Consider the following conditions:
of job
(c) developing the standard method and 1. Minimum wages should be guaranteed
standard time of a job
E 2. Providing incentive to group efficiency
(d) economizing the motions involved on the part performance
of the worker while performing a job. 3. A differential price rate should exist
[ESE : 1995] 4. All standards should be based on optimum
standard of production
E
8.3 Match List-I (Object) with List-II (Tool) and select Those essential for an incentive plan include
the correct answer: (a) 1 and 4 (b) 1 and 2
List-I (c) 3 and 4 (d) 2 and 3 [ESE : 1996]
A. Improving utilization of supervisory staff
D
B. Improving plant layout 8.7 Match List-I (Topic) with List-II (Method of solving)
C. Improving work place layout and select the correct answer using the codes
D. Improving highly repetitive hand movements given below the lists:
List-II List-I
A
1. Micromotion study A. Forecasting

2. Work sampling B. Linear programming
3. Flow process chamber C. Wage incentive
D. Work measurement
M
4. Chronocyclegraph
Codes: List-II
A B C D 1. North-West corner method
2. Rowan plan
(a) 2 3 1 4
(b) 3 2 1 4 3. Method of penalty
4. Time series analysis
(c) 2 3 4 1
(d) 3 2 4 1 [ESE : 1996] 5. Work factor system
Codes:
8.4 Determination of standard time in complex job A B C D
system is best done through: (a) 4 3 1 5
(a) Stop watch time study (b) 4 1 5 3
(b) Analysis of micromotions (c) 4 3 2 5
(c) Group timing techniques (d) 3 1 2 4 [ESE : 1997]
8.8 Match List-I (Charts) with List-II (Details) and 80%. If the relaxation and other allowances were
select the correct answer using the codes given 25%, then the observed time would be:
below the lists: (a) 12.5 min (b) 10 min
List-I (c) 8 min (d) 6.5 min [ESE : 1999]
A. Multiple activity chart
8.11 MTM is a work measurement technique by
B. SIMO chart
(a) Stopwatch study
C. String diagram
(b) Work sampling study
D. MTM
(c) Predetermined motion time system
List-II
(d) Past data comparison [ESE : 1999]
1. Work factor system
Y
2. Movement of material 8.12 Given
3. Motion analysis E = Earning in time Ta
4. Working and idle time of two or more men/ Ta = Actual time of work
S
machines Ts = Standard time set to complete the task
Codes: R = Rate per unit time
A B C D
R
(a) 4 3 1 2 if E = R.Ta + (Ts − Ta ) , then the graph between
A
2
(b) 3 4 2 1
bonus earned and time saved is a:
(c) 4 3 2 1
(a) Straight line (b) Convex curve
(d) 3 4 1 2 [ESE : 1998]
(c) Concave curve (d) Parabola
E
8.9 The type of layout suitable for use of the concept, [ESE : 1999]
principles and approaches of ‘group technology’ is
8.13 A process of discovering and identifying the
(a) Product layout
pertinent information relating to the nature of a
(b) Job-shop layout
specific job is called
(c) Fixed position layout
(a) Job identification (b) Job description
E
(d) Cellular layout [ESE : 1999]
(c) Job analysis (d) Job classification
8.10 The standard time of an operation has been [ESE : 1999]
calculated as 10 min. The worker was rated at

D
Answers Work Study and Work Measurement
8.1 (d) 8.2 (c) 8.3 (c) 8.4 (d) 8.5 (a) 8.6 (a) 8.7 (c) 8.8 (c) 8.9 (d)
A
8.10 (b) 8.11 (c) 8.12 (a) 8.13 (c)
Explanations Work Study and Work Measurement

M
8.1 (d) 8.3 (c)

A rating factor is a factor by which the observed A. Improving utilization of supervisory staff →
time is multiplied in order to adjust for differences work sampling.
in operator’s performance. B. Improving plant layout → flow process
Normal time = observed time × performance chamber.
rating factor. C. Improving work place layout → chronocyle
graph.
8.2 (c)
D. Improving highly repetitive hand movements
Work study investigates work done in an → micromotion study.
organization and it aims at finding the best and
most efficient way of using available resources. 8.5 (a)
It may be divided as Job enlargement occurs along two dimensions,
(i) Method study (ii) Time study vertical and horizontal. Vertical means the worker
is involved with greater ability, responsibility, skill 8.11 (c)

and autonomy required from job holders as in MTM (Method-time measurement) is based on
planning, organizing and inspecting his own work. use of standard time for work elements that have
been predetermined from long period of
8.6 (a)
observation and analysis.
Essential for an incentive plan
1. Minimum wages should be guaranteed. 8.12 (a)
2. All standards should be based on optimum
R
standard of production. E = RTa + (Ts − Ta )
2
Y
8.7 (c) Graph between bonus earned and time saved is
a straight line.
A. Forecasting–Time Series analysis
B. Linear Programming–Method of penalty 8.13 (c)
S
C. Wage incentive–Rowan Plan The correct option is (c) i.e., job analysis.
D. Work measurement–Work factor system
The step involved in job evaluation are:
8.8 (c) Job analysis determine
A
Multiple activity chart: working and idle time of detailed facts about the job
two or more men/machines. ↓
SIMO chart: Motion analysis. Job desctiption describe
String diagram: Movement of material
E
clearly the requirement of job
MTM: Work factor system. ↓
8.9 (d) Job classification
Group technology has become an increasingly
determine the relative worth of job
E
↓
popular concept in manufacturing that is
designed to take advantages of mass production Wages determination compare job with
layout and technique in smaller batch production predetermined job and arrive at suitable
D
system and cellular layout is used in G.T. wage strucure

↓
8.10 (b)
Evaluate performance based
Standard time = 10 mins
A
Normal time = 0.8 × 10 = 8 mins on job description and specification

Observed Job analysis: Job analysis is the process of
⎛ % Allowances ⎞ determining the facts relating to the jobs. It
= Normal time ⎜ 1 + ⎟⎠
⎝
M
100 involves a systematic examination of the job to

find out (1) Nature of tasks performed by the
⎛ 25 ⎞ worker, (2) Purpose or objective of the tasks,
= 8 ⎜1+ = 8 × 1.25 = 10 minutes
⎝ 100 ⎟⎠ (3) Working condition under which the tasks are
carried.

9 Value Engineering
9.1 In value engineering important consideration is (c) 95% (d) 98% [ESE : 1997]
Y
given to
9.5 Consider the following basic steps involved in
(a) cost reduction (b) profit maximization
value analysis:
(c) function concept (d) customer satisfaction
1. Create 2. Blast 3. Refine
[ESE : 1995]
The correct sequence of these steps is
S
9.2 Value is usually considered as a relationship (a) 1, 2, 3 (b) 3, 1, 2
between (c) 1, 3, 2 (d) 2, 1, 3 [ESE : 1997]
(a) Utility and cost
A
9.6 Assertion (A): In case of control charts for
(b) Profit and cost
variables, if some points fall outside the control
(c) Psychology and reliability
limits, it is concluded that the process is not under
(d) Appearance and utility [ESE : 1996]
control.
E
9.3 Aluminium tie pin and gold tie pin, both serve the Reason (R): It was experimentally proved by
purpose of keeping the tie in position. But the Shewhart that averages of four or more consecutive
gold pin has significance due to: readings from a universe (population) or from a
(a) Exchange value (b) Use value process, when plotted, will form a normal
(c) Esteem value (d) Cost value distribution curve.
E
[ESE : 1996] (a) both A and R are true and R is the correct
9.4 If one state occurred four times in hundred explanation of A
observations while using the work-sampling (b) both A and R are true but R is not a correct
D
technique, then the precision of the study using explanation of A

a 95% confidence level will be: (c) A is true but R is false
(a) 90% (b) 92% (d) A is false but R is true [ESE : 1999]
A

Answers Value Engineering
9.1 (a) 9.2 (a) 9.3 (c) 9.4 (d) 9.5 (d) 9.6 (b)
M
Explanations Value Engineering
9.1 (a) It can be seen that value of a product can be

Value engineering is the application of the concept increased either by increasing its utility with the
of value analysis at the design or pre-manufacture same cost or decreasing its cost for the same
stage of the component parts with a view to cut functions.
down the unnecessary cost, without impairing the 9.3 (c)
function or utility of the product.
Esteem V alue: The properties, features or
Value:
9.2 (a) attractiveness of an object makes its ownership
desirable.
Function (or utility) Use V alue: The properties or qualities which
Value:
Value =
Cost accomplish a use, work or service.
Cost V alue: The sum of labour, material and other

Value: 9.5 (d)
cost required to produce the object (also called
Value analysis procedure:
as Economic value).
(a) Blast:
Exchange V alue: The properties or qualities of an
Value:
object that make it possible to exchange it for • Identity the product
something else that one wants. • Collect the relevant informations
• Define the different function
9.4 (d)
(b) Create:
4 • Create different alternatives
P= = 0.04
Y
100
• Critically evaluate the alternative
P⋅S = k⋅σ p
(c) Refine:
(1 − p)p 0.04 × 0.96
σp = = = 0.0196 • Develop the best alternatives
S
n 100
• Implement the alternative
k σp 2 × 0.0196
S= = = 0.979 0.98
p 0.04
∴ Confidence factor is 98%
A
E
E
D
A
M
10 Element of Computation
and Maintenance
10.1 Match List-I with List-II and select the correct List-II
Y
answer using the codes given below the lists: 1. Ritchie 2. Dantzing
List-I 3. Bell 4. Gomory
A. Linear programming Codes:
B. Dynamic programming A B C D
S
C. ‘C’ programming (a) 2 1 4 3
D. Integer programming (b) 1 2 3 4
(c) 2 3 1 4
(d) 2 3 4 1
A
[ESE : 1995]

Answers
E
Element of Computation and Maintenance
10.1 (c)
Explanations Element of Computation and Maintenance

E
10.1 (c)
Linear programming Dantzing

D
Dynamic programming Bell

'C' programming Ritchie
Integer programming Gomory

A
M

1443purl ME ESE-II 1995-1999

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ESE

2. Engineering Materials ......................................................................................... 29-42

3. Mechanisms and Machines ................................................................................ 43-73

4. Design of Machine Elements ............................................................................... 74-96

5. Manufacturing Engineering ............................................................................... 97-129

6. Industrial Engineering and Maintenance Engg. ................................................ 130-154

1. Stress and Strain ................................................................................................................. 2

PLπ 4PL (b) W1 + W2 = Constant

1.5 A tapering bar (diameter of end sections being,

(c) 9 × 30/AE (d) 30 × 22/AE extension if ‘d’ is equal to

subjected to a set of five forces as shown in the

1.6 The deformation of a bar under its own weight as

1.7 A slender bar of 100 mm 2 cross-section is

(δl )total = (δl )1 + (δl )2 + (δl)3 1.6 (c)

Load = Own weight (given) PL

2.1 If Poisson’s ratio of a material is 0.5, then the Eμ Eμ

Answers Stress-strain Relationship and Elastic Constants

Explanations Stress-strain Relationship and Elastic Constants

put μ = 0.5 elastic constant

1. Combined bending and torsion of circular

Answers Principal Stresses and Strains and Mohr’s Circle

3.1 (c) 3.2 (a) 3.3 (c) 3.4 (d)

Explanations Principal Stresses and Strains and Mohr’s Circle

3.1 (c) 3.2 (a)

[ESE : 1996] The maximum circumferential stress in the

(a) joining thick cylinders (c) 65 mm (d) 90 mm [ESE : 1998]

vessels because they [ESE : 1998]

4.10 A thin cylinder with both ends closed is subjected

4.11 If a thick cylindrical shell is subjected to internal

Answers Thin Cylinder and Thick Cylinder

4.10 (c) 4.11 (d)

4.1 (a) 4.3 (c)

pd method, a forged cylinder is subjected to a large

of the cylinder at the inner surface is subjected

4.4 (c) 4.8 (a)

δl σ2 1 σ1 pd 1 pd Principal stresses 2σ0, σ0

inner most radii irrespective of the location of

cantilever AB. The beam and the cantilever carry

is of the same magnitude and of the same

C. Maximum slope 3. WL3/3EI

(d) 4 3 1 2 [ESE : 1996]

5.14 A 2 m long beam BC carries a single concentrated W 2W W

1m 2m 2m 5.19 A lever is supported on two hinges at A and C. It

(c) 50 kgf (d) 60 kgf [ESE : 1997]

5.16 A simply supported beam with width ‘b’ and depth

curve between the supports B and C will be

Answers Shear Force and Bending Moment Diagrams

Explanations Shear Force and Bending Moment Diagrams

5.1 (d) For similar triangle

Rate of change of shear force is equal to the SFD

5.9 (b) 5.12 (d)

Hence this section subjected to pure bending.

stress variation across a cross-section is (B)

(c) square section beam will be stronger

Answers Bending of Beams, Shear Stress Distribution

Explanations Bending of Beams, Shear Stress Distribution

6.1 (a) 24M

D and length L twisted through an angle θ is τ. A (a) T/4 (b) T/8

Answers Torsion of Shafts

Explanations Torsion of Shafts

7.1 (a) for same torque, and identical shaft

Angle of twist is same θ∝ 1

8.1 Match List-I (End conditions of columns) with P