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I.E.S-(Conv.)-2003

MECHANICAL ENGINEERING

PAPER - I
Time Allowed: Three Hours Maximum Marks: 200
Candidates should attempt any FIVE questions. Assume suitable data, if necessary, and indicate them
clearly. Use of Steam Tables, Psychrometric Chart and Refrigeration Tables is permitted.
For air R = 0.287 kJ/kg-K, Cp = 1.005 kJ/kg-K
 = 1.4, M = 28.966 kg/kg-mole

1. (a) Explain the terms (i) coefficient of cubical expansion,  and (ii) coefficient of compressibility
K. Hence, show that /K = (P/T)v.
(5)
(b) Using Maxwell’s and other equations, show that
  u   v  
C p  Cv   P     
  v T  T P 
Hence show that
Cp–Cv = 2 T v/K.
(10)
(c) A reversible engine ‘A’ absorbs energy from a reservoir at temperature T1 and rejects energy
to a reservoir at temperature T2. A second engine ‘B’ absorbs the same amount of energy as
rejected by engine ‘A’, from the same reservoir at temperature T2 and rejects energy to a
reservoir at temperature T3. What will be the relation between T1, T2 and T3 if (i) the
efficiencies of both the engines ‘A’ and ‘B’ are the same and (ii) the work delivered by both
the engines is the same ?
(15)
(d) An ideal gas is heated at constant volume until its temperature is 3 times the original
temperature, then it is expanded isothermally till it reaches its original pressure. The gas is
then cooled at constant pressure till it is restored to the original state. Determine the net work
done per kg of gas if the initial temperature is 350 K.
(10)
2. (a) Make a detailed comparison of S.I. and C.I. engines with respect to basic cycle, fuel,
introduction of fuel in the cylinder, ignition, compression ratio, speed, efficiency and weight.
(15)
(b) Discuss the emissions from S.I. engines and C.I. engines. On what factors do these emissions
depend 7 Discuss how these emissions can be controlled.
(10)
(c) Explain clearly what do you understand by supercharging. How is it achieved ? What is the
effect of supercharging on the following parameters:
(i) Power Output
(ii) Mechanical Efficiency and
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(iii) Fuel Consumption

(15)
3. (a) An iron plate of thickness L and thermal conductivity K is subjected to a constant heat flux q0
W/m2 at the boundary surface at x = 0. From the other boundary surface at x = L, the heat is
dissipated by convection into a fluid at temperature T with a heat transfer coefficient h.
Develop the expressions for the surface temperatures T1 and T2 at the surfaces x = 0 and x =
L, respectively.
For the following data, calculate the surface temperatures T1 and T2 if L = 2 cm, K = 20 W/m
o
C, q0 = 10s W/m2, T = 50°C and h = 500 W/m2 °C.
(15)
(b) Explain clearly what do you understand by the terms velocity boundary layer and thermal
boundary layer. Give their importance in the field of engineering.
The velocity profile for boundary layer flow over a flat plate is given by

 3  y  1 y 
3

U x, y  U       
 2   x  2  x  
If the boundary layer thickness is given by
280 ux
x
13 U 
develop the expression for the local drag coefficient cm over a distance x = L from the leading
edge of the plate.
(15)
(c) Determine the net radiant interchange between two parallel oxidized iron plates, placed at a
distance of 30 mm, having size of 4 m x 4 m. The surface temperatures of the two plates are
1200 C and 40° C respectively. The emissivity of both the plates is 0.736.
(10)
4. (a) An ideal vapour compression refrigerator using Freon-12 operates between temperature limits
of –10° C and 400 C. The refrigerant leaves the condenser dry saturated. The rate of flow of
refrigerant through the unit is 150 kg/hr.
Calculate the refrigerating effect per kg of refrigerant, the coefficient of performance and the
capacity of the plant if,
(i) the refrigerant leaves the condenser dry saturated as stated.
(ii) the refrigerant is sub cooled to 20° C before throttling.
Assume that the enthalpy of refrigerant before throttling is approximately equal to the
enthalpy of liquid refrigerant at under-cooled temperature of 20° C and take it as hf = 50.59
kJ/kg. Give your comments on the result. Solve the problem by using tables.
(25)
(b) Define human comfort. Give the factors governing optimum effective temperature. Outline
the main points considered for cooling load estimate and heating load estimate.
(15)
5. (a) A ship is sailing in the ocean The captain of the ship observes an iceberg floating in the sea at
a distance and he estimates the Visible volume of the iceberg above sea level as 600 m3. If
the density of the iceberg is 915 kg/m3, determine the total volume and weight of the iceberg.
The density of the sea water may be taken as 1025 kg/m3.
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(5)
(b) Explain practical utility of venturimeter and pitot tube. Starting from first principles, derive
the expression for discharge of a liquid through a venturimeter.
If the coefficient of discharge of a venturimeter is 0.96, the venturimeter constant is 0.3
m2.5/sec and venturi head is 0.2 m, find discharge through the venturirneter.
(15)
(c) A city has one million population and water supply to the city is from a reservoir 10 km
away. The minimum required water supply is at the rate of 150 litres per head per day. The
supply is made in two shifts, each being for 8 hours Duration. The full supply level of the
reservoir is R.L. 180.00 and its lowest level is R.L. 105.00. The delivery end of the main is at
R.L. 22.5 m. The head loss at the delivery of the main is 12 m. Find the diameter of the pipe
required. Assume friction factor equal to 0.04.
(20)
6. (a) A circular cylinder of height 200 mm and radius equal to 80 mm is open at the top. It is fixed
on a table at its centre which can be rotated by a motor. Determine the speed of rotation of the
table so that one-third of the area of the bottom of the cylinder gets exposed. At the beginning
of the rotation the cylinder was filled with a liquid.
(10)
(b) A cylindrical tank is placed with its axis vertical. A circular orifice of 40 mm diameter is
fitted at its bottom. The supply of water into the tank is at uniform rate and at the same time
water is discharged through the orifice. A manometer tube is fitted on the side of the tank to
indicate the level of the water. An observer starts the stop watch when water level was at 600
mm. It was found that water level becomes 800 mm after one minute. Again the observer
starts the stop watch when water level was at 1 m and it was found that water level becomes
1.1 m in one minute. Calculate the diameter of the tank by assuming coefficient of discharge
for the orifice equal to 0.6.
(25)
(c) Show that the friction factor is inversely proportional to the Reynolds number in case of
laminar flow in circular pipes. (5)
7. (a) Explain the terms : stable, unstable and neutral equilibrium in reference to the floating bodies.
(6)
(b) Compare the velocity profiles for laminar flow and turbulent flow in pipes and comment on
them.
(4)
(c) A reaction turbine has to be designed to develop 370 kW under a head of 70 m while running
at speed equal to 750 rpm.
Ratio of width of runner to the outer diameter of
runner = 0.1
Ratio of inner diameter to the outer diameter = 0.5
Flow ratio = 0.15
Hydraulic efficiency = 95%
Mechanical efficiency = 84%
Circumferential area occupied by thickness of vanes = 5%
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Assuming velocity of flow constant, calculate guide vane angle at inlet and runner vane
angles at inlet and outlet. The radial velocity is equal to 3.5 m/sec.
(30)
8. (a) Discuss the importance of dimensional analysis Explain clearly Buckingham’s  theorem
method and Rayleigh’s methods of dimensional analysis.
A circular cylinder of a given Length/Diameter ratio is kept in steady rotation at N revol./ sec,
in a uniform stream of fluid of velocity . Assuming that the power required to maintain the
motion depends on density , kinematic viscosity  of the fluid, and the diameter D of the
cylinder. Using Rayleigh’s method show that
 3 vD ND 2 
P f , 
D    
(b) An airplane flies at an altitude with a velocity of 800 km/hr. The pressure and temperature at
that altitude are 1.206 x 10 N/m2 and 217 K respectively. Calculate
(i) the maximum possible temperature on the airplane skin,
(ii) the maximum possible pressure intensity on the airplane body,
(iii) the critical velocity of air relative to the airplane, and
(iv) the maximum possible velocity of the air relative to the airplane.
(8)
(c) Define Froude number, Reynolds number, Mach number, Euler number and Weber number.
(5)
(d) Considering Froude number as the criterion of dynamic similarity for a certain flow situation,
work out the scale factors for velocity, time, discharge, acceleration, force, work and power
in terms of the scale factor for length.
(7)
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I.E.S-(Conv.)-2003

MECHANICAL ENGINEERING
PAPER - II
Time Allowed: Three Hours Maximum Marks: 200
Candidates should attempt Question 1 in Section A which is compulsory, TWO questions from Section B and
TWO questions from Section C.
Question 1 is of short answer type, limiting answer of each part to 30 words.
Assume suitable data, it necessary and indicate them clearly.

SECTION A
1. (a) State the conditions, which should be satisfied to obtain a kinematically equivalent system
with two lumped masses for a connecting rod executing plane motion.
(b) What is meant by hunting in case of engine with governor? Is the degree of hunting more or
less in case of isochronous governor as compared to unstable governor?
(c) What is meant by (i) pressure angle, and (ii) pich point of a cam-follower mechanism?
(d) Define contact ratio of two mating gears and mention its importance in design of gear drive.
(e) How does damping in a single-degree freedom system affect the natural frequency of
vibration ? Explain its expression in terms of system parameters.
(f) Mention the relationship between three elastic constants i.e., elastic modulus (E), rigidity
modulus (C), and bulk modulus (K), for any elastic material. How is the Poisson’s ratio (p)
related to these modulii?
(g) State what is meant by kinematic inversion of a mechanism. Name any one of the inversions
of double slider-crank mechanism, as used in practice.
(h) If a rod of brittle material is subjected to pure torsion, show with help of a sketch, the plane
along which it will fail and state the reason for its failure.
(i) The diameter of a mild steel rod is to be reduced from 70 mm to 65 mm by plain turning in a
single pass at speed of 300 rpm and feed of 0.4 mm/rev. Determine the material removal rate
(MRR) in cubic centimeter (cc)/min that will occur during the aforesaid machining operation.
(j) Keeping the other parameters same, what will be the effect of increasing the diameter of the
straight fluted plain milling cutter on the average uncut chip thickness and why?
(k) How is “Bend Allowance” (BA) calculated in sheet metal working?
(l) How is the wax pattern mode for an investment casting and why is the master pattern made
oversize?
(m) What is meant by Basic Length Unit (BLU) of CNC machine tools? Determine the BLU of a
CNC machine tool whose work-table is moved by a 4 mm pitch lead screw driven by a
stepper motor having 200 steps in one rotation/revolution.
(n) Name any four welding processes which are employed for permanently joining two dissimilar
metals.
(o) How fine through holes of diameter less than 50 microns can be made in 1.0 mm thick
aluminium sheets?
(p) Mention the relative advantageous characteristics of polymer products and their
manufacturing over those of similar metal products.
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(q) Enumerate four purposes of keeping inventory.

(r) What are the properties to be satisfied by a competitive situation to be called a ‘GAME’ with
reference to operation research?
(s) Define “Dynamic Programming” and Bellman’s principle of optimality.
(t) Illustrate the simplest form of ALLOCATION PROBLEM by Three Mathematical
Equations.
(2x20=40)
.

SECTION B
2. (a) Two parallel shafts indicated in figure below are connected by an intermediate shaft with a
Hooke’s joint at each end. Show how the joints should be oriented to obtain a constant
angular velocity ratio between the driving and driven shafts.
The intermediate shaft of the above arrangement has a mass moment of inertia 3 gm2 and is
inclined at 300 to the axes of the driving and driven shafts. If the driving shaft rotates
uniformly at 2400 rpm with a steady input torque of 300 Nm, determine the maximum
fluctuation of the output torque.
(20)

(b) A single cylinder horizontal reciprocating engine mechanism has a crank of 8 cm length and
connecting rod 36 cm length. The engine speed is 2000 rpm clockwise. Determine the
velocity and acceleration of piston when the crank is 315° from inner dead centre. Also
determine the angular acceleration of connecting rod and total acceleration of its midpoint.
Use relative velocity and acceleration method only.
(10)
(c) Determine the addendum of the teeth of a gear pair consisting of two spur wheels each having
30 teeth to have a minimum contact ratio equal to 2. The circular pitch is 2.5 cm and pressure
angle is 200.
(10)
3. (a) A steel bolt of diameter 10 mm passes through a brass tube of internal diameter 15 mm and
external diameter 25 mm. The bolt is tightened by a nut so that the length of tube is reduced
by 1 .5 mm. If the temperature of the assembly is raised by 40°C, estimate the axial stresses
in the bolt and the tube before and after heating. Material properties for steel and brass are :
Es = 2 x 105 N/mm2, s = 1.2 x 10–5/0 C and Eb = 1 x 105 N/mm2, b = 1.9 x 10–5/0 C.
(10)
(b) A solid phosphor bronze shaft 60 mm in diameter is rotating at 800 rpm and transmitting
power. It is subjected to torsion only. An electrical resistance strain gauge mounted on the
surface of the shaft with its axis at 45° to the shaft axis, gives the strain reading as 3.98 x10–4.
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If the modulus of elasticity for bronze is 105 GN/m2 and Poisson’s ratio is 0.3, find the power
being transmitted by the shaft. Bending effect may be neglected.
(10)
(c) Find the slope and deflection at the free end of a cantilever beam of length 6 m as loaded
shown in figure below, using method of superposition. Evaluate their numerical values using
E = 200 GPa, I = 1 x 10–4 m4 and W = 1 kN.
(10)

4. (a) A steel rod of diameter 50 mm is forced into a bronze casing of outside diameter 90 mm,
producing a tensile hoop stress of 30 MPa at the outside diameter of the casing. Find:
(i) the radial pressure between the rod and the casing,
(ii) the shrinkage allowance and
(iii) the rise in temperature which would just eliminate the force fit.
Assume the following material properties: Es = 2 x 105 MPa, S = 0.25, S = 1.2 x 10–5/°C
and Eb = 1 x 105 MPa, b = 0.3, b = 1.9  10–5/°C.
(20)
(b) A cylindrical billet of 40 mm diameter and 100 mm length is reduced by indirect (backward)
extrusion to a 15mm diameter using Flat Dies. If the Johnson equation has a 0.8 and b = 1.5
and the flow curve for the work metal has K = 750 MPa and n = 0.15, determine:
(i) extrusion ratio
(ii) true strain (homogeneous deformation)
(iv) extrusion strain
(iv) ram force.
(c) Mention the major essential constituents of any Flexible Manufacturing System (M F S) used
for production by machining. Also state the basic functions of those constituents (sub
systems).
(10)

SECTION C
5. (a) Compare the solidification time of two optimum side-risers of the same volume when one has
a cylindrical shape and the other is of square parallelopiped.
(20)
(b) Name the processes by which external screw thread can be produced (both manually using
tools and in machines).
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(10)
(c) For resistance spot welding of two aluminium sheets, each 2 mm thick, a current of 5000 A
was passed for 0.15 sec. The total resistance was estimated to be 75  and the nuggest
diameter and thickness were measured to be 5 mm and 2.5 mm respectively. What would be
the proportion of heat energy utilized for welding if the melting energy per unit volume for
aluminium is taken as 2.9 j/mm3 ?
(10)
6. (a) During turning a carbon steel rod of 160 mm diameter by a carbide tool of geometry; 0°, 0°,
10°, 8°, 15°, 75°, 0 (mm) at speed of 400 rpm, feed of 0.32 mm/rev, and 4.0 mm depth of cut,
the following observations were made Tangential component of the cutting force, Pz =
1200N.
Axial component of the cutting force, Px = 800 N
Chip thickness (after cut), 2 = 0.8 mm.
For the above machining condition determine the values of
(i) Friction force, F and normal force, N acting at the chip-tool interface.
(ii) Yield shear strength of the work material under this machining condition.
(iii) Cutting power consumption in kW.
(20)
(b) When a rectangular section, 100 mm wide and 60 mm thick, is rolled to some thickness in
one pass with rolls of 400 mm diameter in hot rolling, where coefficient of friction is 0.3,
(i) What is the highest possible reduction in that pass?
(ii) What will be the ‘length of contact’ with the rolls?
(iii) If the mean rolling pressure is 500 MPa, what is the total rolling load?
(10)
(c) (i) What are the detrimental effects of the high cutting temperature on the machined
product and the cutting tool?
(ii) How can such cutting temperature be reduced with out sacrificing productivity?
(6+4 =10)
7. (a) A certain company produces tea trays and ash trays out of sheet metal. Following data is
given on capacity availability and economics of each product:

Determine the optimum production schedule. Each ash tray contributes Rs. 20 to the gross
profit and each tea tray contributes Rs. 30 to the gross profit. Total daily fixed costs amount
to Rs. 45,000.
Solve this problem graphically. What is the maximum net profit per day at the optimum
production level, including the effect of fixed cost?
(20)
(b) What is a “Trend Line” in sales forecasting by Time Series Analysis?
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In a company the sales figures for a particular product for 16 consecutive quarters were
recorded as follows:

Quarter Units sold

1 1000
2 3000
3 4000
4 2000
5 1000
6 3000
7 5000
8 3000
9 2000
10 4000
11 6000
12 3000
13 2000
14 5000
15 7000
16 4000

Determine the trend line for this product.

(10)
(c) With reference to critical path method define the following terms with a brief description of
each of them
(i) Critical path
(ii) Project graph
(iii) Early start and early finish times.
(10)