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 MECHANICAL ENGINEERING EXAMS PAGE | 1

INDEX
1. BASICS OF MECHANICAL ENGINEERING ............................................................ 3
UNIT 1 CONCEPT OF MECHANICAL TECHNOLOGY ..................................................................................... 4
UNIT 2 WELDING ...................................................................................................................................... 26
UNIT 3 CASTING ....................................................................................................................................... 45
UNIT 4 FORMING PROCESSES .................................................................................................................. 59
UNIT 5 CUTTING TOOLS DESIGN .............................................................................................................. 78

2. THEORY OF MACHINES ...................................................................................... 84

UNIT 1 BASICS OF THEORY OF MACHINE ................................................................................................. 85
UNIT 2 GEAR DRIVES .............................................................................................................................. 100
UNIT 3 BELT DRIVES ............................................................................................................................... 105
UNIT 4 CHAIN DRIVES ............................................................................................................................ 110
UNIT 5 COUPLING .................................................................................................................................. 113

3. MACHINE DESIGN CONCEPTS ..........................................................................119

UNIT 1 INTRODUCTION OF MACHINE DESIGN ....................................................................................... 120
UNIT 2 THEORIES OF FAILURE ................................................................................................................ 125
UNIT 3. BEARING .................................................................................................................................... 127
UNIT 4 SPRING ....................................................................................................................................... 131
UNIT 5 JOINTS ........................................................................................................................................ 133
UNIT 6 DESIGN OF SCREW AND BOLT .................................................................................................... 136
UNIT 7 COMBINE STRESS ....................................................................................................................... 138
UNIT 8 DESIGN OF SHAFT & SPRING & KEY ........................................................................................... 140

4. STRENGTH OF MATERIAL ................................................................................. 141

UNIT 1 INTRODUCTION .......................................................................................................................... 142
UNIT 2 STRESS AND STRAIN ................................................................................................................... 151
UNIT 3 SHEAR FORCE & BENDING MOMENT ......................................................................................... 158
UNIT 4 SLOPE AND DEFLECTION OF BEAM ............................................................................................ 164
UNIT 5 PRINCIPAL STRESSES .................................................................................................................. 167
UNIT 6 DIRECT SHEAR STRESSES ............................................................................................................ 173
UNIT 7 SHAFT AND HELICAL SPRING ...................................................................................................... 174

5. FLUID MECHANICS............................................................................................ 177

UNIT 1 PROPERTIES OF FLUID ................................................................................................................ 178
UNIT 2 BUOYANCY ................................................................................................................................. 186
UNIT 3 PRESSURE MEASUREMENT ........................................................................................................ 190
UNIT 4 FLUID DYNAMICS ....................................................................................................................... 196
 MECHANICAL ENGINEERING EXAMS PAGE | 2

UNIT 5 UNIFORM FLOW ......................................................................................................................... 201

UNIT 6 NON UNIFORM FLOW ................................................................................................................ 203
UNIT 7 FLOW THROUGH PIPE ................................................................................................................ 204

6. HYDRAULIC MACHINERY ................................................................................ 207

UNIT 1 TURBINE ..................................................................................................................................... 208
UNIT 2 PUMPS........................................................................................................................................ 214

7. MANUFACTURING PLANNING AND CONTROL ............................................... 219

UNIT 1 INDUSTRIAL ENGINEERING ........................................................................................................ 220
UNIT 2 MANUFACTURING PLANNING AND CONTROL ........................................................................... 227
UNIT 3 FORECASTING ............................................................................................................................. 235
UNIT 4 MATERIAL REQUIREMENT PLANNING ....................................................................................... 238
UNIT 5 SCHEDULING AND SEQUENCING ................................................................................................ 243
UNIT 6 PROJECT MANAGEMENT ............................................................................................................ 248
UNIT 7 ADVANCE CONCEPT OF PRODUCTION PLANNING 1 AND 2 ....................................................... 254

8. IC ENGINE ......................................................................................................... 259

UNIT 1 IC ENGINE ................................................................................................................................... 260
UNIT 2 CYCLES IN IC ENGINE .................................................................................................................. 266
UNIT 4 SUPERCHARGING AND TURBOCHARGING ................................................................................. 274
UNIT 5 COMBUSTION IN IC ENGINE ....................................................................................................... 276
UNIT 6 COOLING LUBRICATION & IGNITION SYSTEM ............................................................................ 279

9. THERMAL ENGINEERING .................................................................................. 283

A] THERMODYNAMICS ........................................................................................................................... 283
B] REFRIGERATION AND AIR CONDITIONING......................................................................................... 300
C] POWER PLANT ................................................................................................................................... 318

10. AUTOMOBILE .................................................................................................. 328

UNIT 1 PARTS OF VEHICLE...................................................................................................................... 329
UNIT 2 TRANSMISSION .......................................................................................................................... 333
UNIT 3 CHASSIS FRAME AND BODY ....................................................................................................... 338
UNIT 4 POWER TRANSMISSION SYSTEM ............................................................................................... 342
UNIT 5 BRAKING SYSTEM ....................................................................................................................... 350
UNIT 6 STEERING SYSTEM ...................................................................................................................... 358
UNIT 7 SUSPENSION SYSTEM ................................................................................................................. 365
UNIT 8 ELECTRICAL SYSTEM ................................................................................................................... 370

11. MOST EXPECTED MCQS .................................................................................. 376

12. TCS/IBPS PATTERN PREVIOUS YEAR QUESTIONS ....................................... 461

 MECHANICAL ENGINEERING EXAMS PAGE | 3

1. BASICS OF MECHANICAL ENGINEERING

BASICS OF MECHANICAL
ENGINEERING
 MECHANICAL ENGINEERING EXAMS PAGE | 4

1
UNIT 1 CONCEPT OF MECHANICAL TECHNOLOGY
BASICS OF MECHANICAL ENGINEERING

MILLING i) Up Milling (Or Conventional Milling)

Process

i)Milling is a machining process in which metal

is removed by means of a revolving cutter with
many teeth, each tooth having a cutting edge
which removes metal from a work piece.
ii)In milling process, the work is supported by
various method on the worktable of milling
machine and fed into a rotating cutting tool
known as milling cutter.
iii)Equally spaced peripheral teeth on the cutter i)In this up milling process, the work piece is fed
come in contact with the work piece opposite to the cutter’s tangential velocity.
intermittently and machine the work piece and is ii)Each tooth of the cutter starts the cut with zero
called intermittent cutting. depth of cut, which gradually increases and
iii)In some milling machines, the work piece reaches the maximum value as the tooth leaves
remains stationary and the cutter is fed into the the cut. The chip thickness at the start is zero
work piece. increases to maximum at the end of the cut.
Parts having flat, curved and intricate shapes, ii)The action of the cutter, forces the work piece
can be machined on the milling machine. and the table against the direction of table feed,
thus each ‘tooth’ enters a clean metal gradually
thus the shock load on each tooth is minimised.
iii)Difficulty is experienced in pouring coolant on
the cutting edge and as a result, chips
accumulate at the cutting zone and may be
carried over with the cutter, thus spoiling the
surface finish. The surface becomes slightly
wavy, as the cut does not begin as soon as the
cutter touches the work piece.
iv)While making deep cuts, the cutter tends to
MILLING PROCESSES pull the work piece out of the vice or the fixture,
There are two types of milling processes because the cutting force is directed upward at
I) Up milling (or conventional milling) process an angle; This requires secured clamping of work
ii) Down milling (or climb milling) process. piece.
 MECHANICAL ENGINEERING EXAMS PAGE | 5

ii) Down Milling (Or Climb Milling) (iv) Omniversal milling machine
Process
Manufacturing or fixed bed type
(i) Simplex milling machine
(ii) Duplex milling machine
(iii) Triplex milling machine
Simplex, duplex or triplex machines
These are smaller versions of planer type milling
machines. In simplex milling machine one
spindle is on one side, in duplex milling machine
two spindles on two sides and in triplex milling
In down milling process the work piece is fed in machine two spindles on two sides and one on
the same direction as that of the cutter’s the overhead.
tangential velocity. The cutter enters the top of These machines are larger, heavier and have
the work piece and removes the chip that gets greater rigidity than the column and knee type
progressively thinner as the cutter tooth rotates. and are not adapted to tool room.
Advantages of down milling process:

• The cutting force of the cutter tends to

hold the work piece against the machine table
due to which lower clamping forces are required
to clamp the work piece.
• Down milling produces better finish and
better dimensional accuracy.
• Coolant can be fed easily.
• The chips are disposed off conveniently
and they do not interfere with the cutting due to Planer type
which the machined surface of the work piece is This machine looks like a double column planer,
not spoiled. but has milling heads mounted in various planes,
Down milling is performed on the materials that vertical milling heads on cross rail and horizontal
are free from the scales and surface heads at the sides. Due to which it can machine
imperfections. a work piece on sides simultaneously.
This machine is primarily intended for producing
CLASSIFICATION OF MILLING MACHINES long straight surfaces on large and heavy
machine parts.
Milling machines are classified as below:
Special type
Column And Knee Type
(i) Rotary table milling machine
(i) Horizontal milling machine
(ii)Drum milling machine
(ii) Vertical milling machine
(iii) Planetary milling machine
(iii) Universal milling machine
 MECHANICAL ENGINEERING EXAMS PAGE | 26

2
UNIT 2 WELDING
WELDING
1. Autogenous process: No filler material is
WELDING added during the joining
2. Homogeneous process: This process
Welding is a localised coalescence of similar of
makes use of filler metal but of same
dissimilar metals, wherein coalescence is
composition as the parent metal
obtained by with or without application of heat
3. Heterogeneous process: The filler
and pressure, with or without the use of filler
material is soluble in both the parent metals
metal. The filler metal has melting point
which themselves are insoluble in each other.
approximately same as the base metal.
Based on the composition of the joint after
welding, welding can be classified as,

CLASSIFICATION OF WELDING PROCESS

 MECHANICAL ENGINEERING EXAMS PAGE | 136

6 DESIGN OF SCREW & BOLT

UNIT 6 DESIGN OF SCREW AND BOLT

Basically most important joints forms are two III)’V’ threads the cheaper, because of easiness
type one is threaded joint & another one is to cut by die or on machine.
welded Joint In this chapter we are going to TERMINOLOGY FOR SCREW THREADS
study the design of this two joints. 1)Major Diameter (do) = It is the longest dimeter
THREADED JOINT by which screw is specified.
I)This type of Joint is formed by cutting 2)Minor Diameter (dc) = It is smallest diameter of
contineous helical groove on cylindrical external & internal screw threads also called as
Surface, when there is single helical groove is root or come diameter.
called as single stort threaded Screw Then. 3)Pitch Circle Diameter(de) = It is an imaginary
there is space between grooves of the first the diameter of cylinder on Cylindrical screw thread
it is called as double started threaded screw. as the surface pass through thread at Such
II)Screwed joint is mainly composed of two point as make equal width of thread & width of
elements. Screw & (bolt) & nut. space between thread.
III)These type of joints are used in machine port 4)Pitch= It is nothing but a distance between
to readily connect & disconnect machine part one point on one thread to corresponding point
without causing any damage to machine or on another or next thread
fastening. 1
𝑝 = 𝑁𝑜 𝑜𝑓 𝑡ℎ𝑟𝑒𝑑𝑠 𝑝𝑒𝑟 𝑢𝑛𝑖𝑡 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑠𝑐𝑟𝑒𝑤
APPLICATIONS OF SCREWED THREAD 5)lead= It is defined as distance through which,
JOINTS a screw advance axially in one rotation of nut.
I) Threads having high strength & low efficiency Lead =2x pitch
so Loosing during Service so it used in radially
joint.
II)It also helpful in transmitting power or energy
because of high efficiency.
various forms of threads-
1) whit worth thread
2) Buttress thread
3) knuckle thread
4)Acme thread
5) square thread
TYPE OF SCREW FASTENING
out of this 'v' thread & square threads be used.
I)Because ‘V’ threads used in bolts, a studs, There are three type of Screw Fastening
nuts, tighten the Parts together. 1)Through bolt
II)’V’ threads are stronger than Square thread. 2) Tap bolt
 MECHANICAL ENGINEERING EXAMS PAGE | 283

9. THERMAL ENGINEERING

A] THERMODYNAMICS

THERMAL ENGINEERING
A] THERMODYNAMICS
 MECHANICAL ENGINEERING EXAMS PAGE | 284

1
UNIT 1 BASICS OF THERMODYNAMICS

BASICS OF THERMODYNAMICS
Thermodynamics is branch of science which
deals with 3E ENTROPY
i.e.,
1st E-Equilibrium i) entropy is degradation of heat energy.
2nd E-Energy ii) Basically, entropy is the loss of energy of
3rd E -Entropy system.

EQUILIBRIUM SYSTEM
(i) It simply means balance Any kind of Balance System is controlled region & space over which
our attention of Focus.
is equilibrium like balance of forces, balance
reaction, etc. i) Basically, System is region in Space in which
we are focusing our study
(ii) Thermodynamic equilibrium means balance
of thermal, mechanical, chemical Equilibrium. SURROUNDING
(iii) Thermal equilibrium means equality of - everything which is not part of system is
temperature Surrounding
(iv) mechanical equilibrium means equality of BOUNDARY
force It is the region which is separating system from
(v) chemical equilibrium means Stability in Surrounding Boundaries can be real or
chemical potentials imaginary. Boundaries can be fixed or movable:
Note- ii) Boundaries are having zero thickness.
If in Exam, question is asked about equilibrium universe- universe is nothing but a consideration
then of Summation of System & Surrounding.
1)IF they ask Thermal equilibrium, then there is Types of System -There are 3 type of system.
equality of Temperature. 1) close system
2)If they ask thermodynamic equilibrium then 2) open System
there is all their equilibrium, exist that is thermal, 3) isolated system
mechanical &chemical equilibrium. 1)close system
i) It is type of by system where only Energy Can
ENERGY transfer from the system, but mass is not
Energy is nothing but a capacity to do work. capable of transfer from the systems but get into
In thermodynamics we deal with thermal energy the Systems
of any Component/System. ii)Only energy interaction between System &
Surrounding.
 MECHANICAL ENGINEERING EXAMS PAGE | 379

THEORY OF MACHINES
1. The relation between the no. of pairs (p) 1, p and q, then it would result in Grasshof's
forming a kinematic chain and the no. of links (1) linkage provided that:
is A. l+p<s+q B. l+s<p+q
A. 1=2p-2 B. 1=2p-3 C. l+p=s+q D. None of these
C. 1=2p-4 D. 1=2p-5 9. In kinematic chain, a quarternary joint is
2. The Grubler's criterion for obtaining the degree équivalent to
of freedom (F) of a planar mechanism with 'n' A. one binary joint
number of links and 'j' number of binary joints, is B. two binary joints
given by: C. three binary joints
A. F=3(n-1)-j B. F=3(n-1)-2j D. six binary joints
C. F=2(n-1)-j D. F=2(n-1)-2j 10. The number of degree of freedom of a five
3. A planar mechanism has 8 links and 10 rotary link place mechanism with five revolute pairs as
Joints. The number of degrees of freedom of the shown in the figure is
mechanism, using Grubler's criterion, is:
A. 0 B. 1 C. 2 D. 3
4. Mechanism is said to be converted to
structure if the degree of freedom of mechanism A. 3 B. 4
reduced to: C. 1 D. 2
A. 3 B. 1 C. 0 D. 2
11. A planar linkage having 8 links and 9 joints of
5. If the elements of a kinematic pair make single degree of freedom will have degree of
surface contact when in motion, then it is called freedom.
a: A. 1 B. 2 C. 3 D. 4
A. Lower pair B. Closed pair
12. A mechanism is an assemblage of:
C. Higher pair D. Surface pair
A. three links
6. Inversion of a mechanism means B. four links or more than four links
A. turning it upside down C. None of three mentioned here.
B. fixing different links in a kinematic chain D. two links
C. changing a higher pair to lower pair
13. Which of the following is the inversion of
D. changing the input and output links
double slider crank chain?
7. In a four-bar chain or quadratic cycle chain A. Beam Engine
A. each of the four pairs is a turning pair B. Elliptical Trammel
B. one is a turning pair and three are sliding pairs C. Watt's indicator mechanism
C. two are turning pairs and two are sliding pairs D. Quick return mechanism
D. three are turning pairs and one is a sliding pair
14. The following is not the inversion of slider
8. In a 4- bar linkage, if the lengths of shortest, crank mechanism
longest and the other two links are denoted by s,
 MECHANICAL ENGINEERING EXAMS PAGE | 449

POWER PLANT ENGINEERING

1. The efficiency of superheat Rankine cycle is 7. An air preheater is installed
higher than that of simple Rankine cycle A. before the economiser
because. B. before the superheater
A. the enthalpy of main steam is higher for C. between the economiser and chimney
superheat cycle D. none of these
B. the mean temperature of heat addition is 8. In a Rankine cycle, regeneration results in
higher for superheat cycle higher efficiency because
C. the temperature of steam in the condenser is A.Pressure inside the boiler increases
high B. Heat is added before steam enters the low
D. the uality of steam in the condenser is low. pressure turbine
2. Which of the following is a water-tube boiler? C. Average temperature of heat addition in the
A. Cochran boiler boiler increases
B. Babcock and Wilcox boiler D. Total work delivered by the turbine increases
C. Lancashire boiler 9. Reheat factor is defined as the:
D. Locomotive boiler A. ratio of cumulative enthalpy drop to isentropic
3. In steam power cycle, reheat factor is usually enthalpy drop
in the range: B. product of cumulative entropy drop to
A. 1.02 to 1.05 B. 1.12 to 1.15 isentropic enthalpy drop
C. 1.5 to 1.8. D. 1.9 to 2.1 C. ratio of isentropic enthalpy drop to cumulative
4. In steam power cycle, the process of removing enthalpy drop
non-condensable gases is called D. sum of isentropic and cumulative enthalpy
A. scavenging process drops
B. deaeration process 10. The thermal efficiency of an ideal Rankine
C. exhaust process cycle is less than that of Carnot cycle operating
D. condensation process between the same maximum and minimum
5. Thermal power plant works on temperature limits because:
A. Carnot cycle A. Heat addition does not takes place at constet
B. Joule cycle temperature
C. Rankine cycle B. The expansion process is not reversible z
D. Brayton cycle adiabatic
6. Reheating of Rankine Cycle will C. Heat rejections does not take place constant
A. not alter turbine efficiency temperature
B. improve the steam uality D. The compression process is not reversible
C. decrease the nozzle and blade efficiency and adiabatic.
D. decrease the turbine efficiency