GATE WALLAH

ESE-2024
MAIN EXAM DETAILED SOLUTION

MECHANICAL ENGINEERING

PAPER-II EXAM DATE - 23 June 2024

2 : 30 PM to 5 : 30 PM

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 MECHANICAL Engineering — (Paper-II)
SECTION-A
Q.1. (a) Find the support reaction at the fixed end A of the loaded beam:

Sol. 1. (a)

For static equilibrium

FH = 0
RAH + 43.30 = 0
RAH = –43.30 N
Negative sign shows our assumed direction is wrong. Change the direction of RAH
FV = 0
RAV – 30 – 25 – 24 = 0
RAV = 79 N
MA = 0
–MA + 15 + 24 × 0.8 + 30 × 1 + 25 × 2.1 = 0
MA = 116.7 Nm PAGE
1

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 MECHANICAL Engineering — (Paper-II)

(b) The straight bar AD of uniform cross-section is attached to the rigid end supports. Find
the force acting on any cross-section in the regions AB, BC and CD:

Sol. 1. (b) Uniform cross-section rigid support

To get force in any cross-section, we will use method of section.

Applying reaction at support A and D.

Internal force calculation.

PAB = RA OR 18 – 54 – RD = – 36 – RD
PBC = RA – 18 OR – 54 – RD
PCD = RA – 18 + 54 OR – RD
= RA + 36
Since it is fixed from both ends
CD = 0 (compatibility equation)
AB + BC + CD = 0
 PL   PL   PL 
  +  +  =0
 AE AB  AE BC  AE CD
RA × 0.9 + (RA – 18)0.6 + (RA + 36) × 0.9 = 0
[AEAB = AEBC = AECD]
2.4 RA = –21.6 kN
RA = –9 kN
FH = 0 (Static equilibrium equation)
RA – 18 + 54 + RD = 0
–9 – 18 + 54 = –RD
PAGE
RD = –27 kN 2

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 MECHANICAL Engineering — (Paper-II)
Since RA and RD is negative, our assumed direction is wrong.

Internal force is AB
PAB = –9 kN

AB member is under compression

PBC = 9 – 18 = –27 kN

BC member is under compression

PCD = 27 kN

CD member is under tension.

(c) (i) Determine the degrees of freedom of the following planar linkages/ kinematic chains:

Sol. (c) (1)

PAGE
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 MECHANICAL Engineering — (Paper-II)
l=6
j=7
h=0
f = 3(l – 1) – 2j – h
= 15 – 14 – 0
F =1
(2)

l=8
j = 10
h=0

f = 3 (8–1) – 2 × 10 – 0
F =1
(3)

l=4
j=4
h=0
f = 3 (l–1) – 2j – h
= 3 (4–1) – 8 – 0
F =1
(4)

l=8
j = 10
h=0
f = 3(8–1) – 2 × 10 – 0
F =1
(5)

PAGE
l=6
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 MECHANICAL Engineering — (Paper-II)
j=7
h=0
f = 3(6–1) – 2 × 7 – 0
F =1
(6)

l=8
j = 10
h=0
f = 3(8–1) – 2 × 10 – 0
F =1
(c) (ii) Determine and show the structurally distinct (unique) inversions of the following 8-
link kinematic chain:

Sol. (c) (ii) The kinematic chain consists of 8 links. By fixing one link to the ground each time
and excluding symmetric mechanisms, a unique mechanism is created. The chain is
symmetric about links 3 and 7, resulting in identical mechanisms when links 2, 1, 8,
or 4, 5, 6 are fixed. Additionally, two more unique mechanisms can be derived from
the 8-link kinematic chain by fixing links 3 and 7 in turn, as illustrated in the figure
below. Hence, a total of 5 unique inversions may be obtained.

PAGE
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 MECHANICAL Engineering — (Paper-II)
(d) The turbine rotor of a ship has a mass of 2.5 tonnes and rotates at 1750 r.p.m. clockwise
when viewed from the aft. The radius of gyration of the rotor is 320 mm. Determine the
gyroscopic couple and its effect when (i) the ship turns right at a radius of 250 m with a
speed of 30 km/hr, (ii) the ship pitches with the bow rising at an angular velocity of 0.7
rad/s and (iii) the ship rolls at an angular velocity of 0.2 rad/s.
Sol. (d)
m = 2.5 tonnes = 2500 kg
1750
 = 2  = 183.25 rad/s (cw)
60
k = 0.32 m
(i) When ship turns right:
R = 250 m
5
V = 30 km/hr = 30 × m/s = 8.33 m/s
18

T = Iωωp = (mk 2 ) 
V
R
 8.33 
 T = (2500  0.322 )  183.25   
 250 
 T = 1563.12 N.m
Effect  Bow of ship will go down.
(ii) When ship pitches with bow rising:
T = Iωωp
 T = 2500 × 0.322× 183.25 × 0.7 = 32838.4 N-m
Effect  Bow will be thrown towards right.
(iii) When ship rolls  No gyroscopic effect

(e) What is the relationship between tensile and shear yield stresses as per (i) von Mises'
criterion and (ii) Tresca's criterion?
The above relationships are to be derived by considering yielding under uniaxial tensile
loading and under pure torsion.
Sol. (e) Tensile strength (y)

Figure: Uniaxial tensile load

Stress in critical point at yielding

Principal stresses under uniaxial tensile load at yielding.

1 = y, 2 = 0, 3 = 0
Shear strength (y)

PAGE
Figure: pure torsion 6

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 MECHANICAL Engineering — (Paper-II)
Stress critical point at yielding

xx = 0
yy = 0
xy = y
Principal stresses under pure torsion at yielding
 xx +  xy   xx −  xy 
2

1,2 =    +  xy and 3 = 0
2

2  2 

0+0 0 − 0
2

1,2 =    +  y and 3 = 0
2

0  2 
1, 2 = 0  y and 3 = 0
1 = y, 2 = −y, 3 = 0
(i) Von-Mises criteria
Criteria of failure: Distortion energy/volume (ud)
Distortion energy/volume under uniaxial load [ud) uniaxial]
1
u duni axial = 12 +  22 + 32 − (1 2 +  2 3 + 13 )
6G 
1
=  2y + 0 + 0 − (0 + 0 + 0)
6G 
1
u d uni axial =  2y 
6G
Distortion energy/volume under pure torsion [ud) torsion]
1
u d torsion = 12 +  22 + 32 − (1 2 +  2 3 + 1 3 )
6G
1  2
( ) ( )
+ 0 − ( y )(− y ) + 0 + 0 
2
u d torsion =  + −
6G  
y y

1
udpure torsion = 3 2y 
6G
As per von Mises criteria
u d pare torsion = u d uniaxial


1
6G
(32y ) = ( y )
1 2
6G
2 y
 2y =
3
y
 y = PAGE
3 7

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 MECHANICAL Engineering — (Paper-II)
(ii) Tresa’s criteria

Criteria of failure : maximum shear stress  max

Maximum shear stress under uni-axial load ( max ) uniaxial

  −  2  2 − 3 1 − 3 
max = max  1
2 
, ,
uni axial
 2 2

 y − 0 0 − 0 y − 0 
= max  , , 
 2 2 2 

y
max =
uniaxial
2

Maximum shear stress under pure torsion

(max ) 
 pure torsion 

(max )  = max  1 −  2 ,  2 − 3 , 1 − 3 
 pure torsion 
 2 2 2 

  y − (− y ) − − 0  − 0 
= max  
y y
, ,
 2 2 2 
 

(max )pure torsion = y

As per Tresa’s criteria

(max )pure torsion = (max )uniaxial

y
 y =
2

Q.2. (a) A smooth sphere of mass 1.5 kg is released from rest in the position when the flexible
string attached to it is horizontal. It hits centrally a stationary block of mass 1.8 kg kept
on a surface, with the coefficient of friction between the block and the surface being 0.3.
If the coefficient of restitution is 0.8, how far would the block move after impact?

PAGE
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 MECHANICAL Engineering — (Paper-II)
Sol. (a) m = 1.5 kg, M = 1.8 kg,  = 0.3, e = 0.8

speed of sphere at position A (vA) = 0

By conservation of energy
1 1
mv 2A + mgh = mv B2
2 2
1
 0 + 1.5  9.81  1.2 =  1.5  v 2B
2
 vB = 4.852 m/s
Velocity of block before impact (VB) = 0
let vB and VB ' are the velocities of sphere and block after the impact.
By conservation of linear momentum
 m v B + M VB = m v B'+ M VB '
 1.5  4.852 + 0 = 1.5v B '+ 1.8VB '
 1.5v B '+ 1.8VB '= 7.278 - - - (i)
Coefficient of restitution is given as:
VB ' − v B'
e=
v B − VB
VB ' − v B '
 0.8 =
4.852 − 0
 VB ' − v B' = 3.882 - - - (ii)
from equation (i)and (ii)
v B ' = 0.088 m/s VB ' = 3.97 m/s

Velocity of block at position C (vC) = 0

By work energy theorem;
Work done by friction = Change in kinetic energy of block
1 1
−f  S = M VC2 − M VB ' 2 PAGE
2 2
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 MECHANICAL Engineering — (Paper-II)

M (VC2 − VB ' 2 )
1
 – mg ×S =
2

 − 0.3  1.8  9.81  S =  1.8  (0 2 − 3.97 2 )

1
2
 S = 2.68 m
(b) (i) Derive the formulation for path of contact of two gears A and B in contact as shown
in the figure:

Sol. (b) (i) Assuming pinion is driver in the given figure. The contact between the two teeth
occurs where the addendum circle of the wheel intersects the line of action EF, at
point C. The contact is broken where the addendum circle of the pinion intersects
the line of action EF, at point D. Thus, CD represents the path of contact.
CD = CP + PD
Where, CP is the path of approach and PD is the path of recess.
Path of approach (CP)
In BCF;
BC2 = BF2 + CF2
 R a2 = (CP + PF) + (R cos )
2 2

 (CP + R sin  )2 = R a2 − (R cos )

2

 CP = R a2 − (R cos ) − R sin 
2

Similarly
Path of recess (PD)
In ADE;
AD2 = DE2 + AE2
 ra2 = (DP + PE) + (r cos )
2 2

 (DP + r sin  )2 = ra2 − (r cos )

2

 DP = ra2 − (r cos ) − r sin 

2

Hence, Path of contact is given as;

DC = ra2 − (r cos ) − r sin  + R a2 − (R cos ) − R sin 

2 2
PAGE
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 MECHANICAL Engineering — (Paper-II)
(b) (ii) Each of two gears in a mesh has 48 teeth and a module of 8 mm. The teeth are of 20°
involute profile. The arc of contact is 2.25 times the circular pitch. Determine the
addendum and contact ratio.
Sol. (b) (i) t = 48, T = 48
m = 8 mm,  = 20°
AOC = 2.25 PC
mt 8  48
r=R= = = 192 mm
2 2
AOC
Contact ratio = = 2.5
PC
Path of contact;
POC = KP + PL = 2KP (⸪ KP=PL in this case)

 (AOC) cos  = 2 rA2 − (r cos ) − r sin 

2

 (2.25   8) cos 20 = 2 rA2 − (192cos 20) − (192sin 20)

2

 rA = 202.63 mm

Addendum = rA – r = 202.63 – 192

 Addendum = 10.63mm
(c) A cam having a lift of 1.2 cm operates the suction valve of a four-stroke petrol engine.
The least radius of the cam is 2 cm and nose radius is 0.3 cm. The crank angle of the
engine when suction valve opens is 4º after t.d.c. and it is 50° after b.d.c. when the suction
valve closes. The camshaft has a speed of 960 r.p.m. The cam is of circular type with
circular nose and flanks. It is integral with camshaft and operates a flat-faced follower.
Calculate (i) the maximum velocity of the valve, (ii) the maximum acceleration and
retardation of the valve and (iii) the minimum force to be exerted by the spring to
overcome inertia of the valve parts which weigh 250 g.
Sol. (c) (i) Lift (x) = 1.2 cm = 12 mm
least radius r1 = 20 mm
nose radius r2 = 3 mm
camshaft speed, N = 960 rpm
suction value opens 4° after TDC
suction value opens 50° after BDC
valve part inertia = 0.25 kg

PAGE
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 MECHANICAL Engineering — (Paper-II)
Angular displacement of crank when suction valve is open
= 180° – 4° + 50° = 226°
In four-stroke engines, cam shaft speed is half of the crankshaft speed.
 angular displacement of cam shaft during opening of the suction valve
226
= = 113 = 2
2
Since the cam is a symmetrical;
angle of ascent = angle of descent
113
Angle of ascent  = = 56.5
2

OP + r2 = lift +r1
 OP = 12 + 20 – 3 = 29 mm = d
flank radius;
r 2 − r22 + d 2 − 2r1d cos 
R= 1
2 (r1 − r2 − d cos )
202 − 32 + 292 − 2  20  29cos 56.5
 R=
2 (20 − 3 − 29cos 56.5)
591.753
 R=
1.98765
 R = 297.714 mm
flank angle from triangle OQP
PO PQ
=
sin  sin (180 − )
sin (180 − 56.5)  29
 sin  =
(297.714 − 3)
 sin  = 0.082054 PAGE
  = 4.7066° 12

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 MECHANICAL Engineering — (Paper-II)
(i) Maximum velocity when follower leaves the flank ( = )
vmax = 𝜔(R–r1) sin
2N
=  (297.7149 − 20) sin 4.7066
60
2  960
=  (297.7149 − 20) sin 4.7066
60
= 2.29 m/s
(ii) Maximum acceleration of value when  = 0
acceleration a = 𝜔 2 (R–r1) cos
 2  960 
2

  (297.714 − 20) cos 0


=
 60 
= 2806.718 m/s2
Retardation is maximum when (–) = 0
a = – 𝜔 2d
 2  960 
2
−3
=   29  10
 60 
= –293.087 m/s2
(iii) Minimum force to be exerted by the spring to overcome inertia of the valve parts
Minimum force = Mass × Retardation
= 0.25 × (293.087)
minimum force = 73.271 N
Q.3. (a) Show the loading on the beam corresponding to the bending moment diagram shown in
the figure. The beam is simply supported at A and B:

Sol. 3. (a)

PAGE
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 MECHANICAL Engineering — (Paper-II)
Sign convection
Bending moment

Shear Force

At A, bending moment is dropping suddenly by 1500 Nm, therefore at A, a

concentrated couple of 1500 Nm acts in ACW direction.
Between AC, BMD is inclined line, which means the slope of BMD is constant,
therefore in AC region shear force is constant (Say FAC).
FAC = Slope of BMD is AC region
B.M.)C − B.M.)A,R
 FAC =
3
750 − ( −1500)
 FAC =
3
 FAC = 750 N
Reaction calculation:
SA,R – SA,L = +RA
720 – 0 = +RA
RA = 750 N
At just right of C, slope of BMD is 0, therefore shear force at just right of C should
be 0.
Now at C, there is sudden of shear force of height 750 N, therefore concentrated
force of P = 750 N should act in downward direction AC.
From just right of C(C, R) to just left of B(B, L) i.e., in CB region sign of slope of
BMD is negative, therefore shear force value in CB region is negative.
And from C, R to B, L magnitude of slope of BMD is increasing therefore magnitude
of shear force will increase as shown in figure.
Since in CB region SFD in inclined line with negative slope, therefore in CB region
UDL of intensity w N/m will act in downward direction.
MB = 0
3
 RA × 6 – 1500 – 750 × 3 – w × 3 × = 0
2
 750 × 6 – 1500 – 2250 – 4.5 w = 0
 750 = 4.5 w
750
 w=
4.5
PAGE
 w = 166.667 N/m
14

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 MECHANICAL Engineering — (Paper-II)
Now, Fy = 0
 RA – 750 – w × 3 + RB = 0
 750 – 750 – 166.667 × 3 + RB = 0
 RB = 500 N
Therefore, correct loading diagram

(b) A shaft 1.7 cm diameter and 1.2 m long is held in long bearings. The weight of a disc at
the centre of the shaft is 20 kg. The eccentricity of the centre of gravity of the disc from
centre of rotor is 0.03 cm. The Young's modulus of material of the shaft is 2 ×106 kg/cm².
The permissible stress in the shaft material is 750 kg/cm². Calculate (i) the critical speed
of the shaft and (ii) the range of speed over which it is unsafe to run the shaft. Neglect
weight of the shaft.
Sol. (3) (b)
m = 20 kg, L = 1.2 m
d = 1.7 cm = 0.017 m
e = 0.03 cm = 0.0003 m
Assuming g = 9.81 m/s2
per = 750 kg/cm2 = 73.575 MPa
E = 2 × 106 kg/cm2 = 196200 MPa
(i) Since the shaft is supported by long bearings, it can be considered fixed at both ends.
Static deflection of the shaft due to the weight of the disc is given as;

mgL3
=
192EI
20  9.81  1.23
 = = 0.002195m

192  196200  10   (0.017)
6 4
64
Critical Speed = Natural frequency
1 g 1 9.81
 fc = = = 10.64Hz
2  2 0.002195
Critical speed in rpm;
Nc = 60f c = 60 10.64 = 638.4 rpm
(ii) When the shaft rotates, the additional dynamic load can be determined using the
following relationship:
M  per
=
I y
W1L
8  per
 =

 d4 d / 2 PAGE
64
15

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 MECHANICAL Engineering — (Paper-II)

W1  1.2 73.575  106

 =
  0.017 
8   (0.017) 4  
64  2 
 W1 = 236.584 N
Additional deflection due to this load;
W 236.584
y = 1  =  0.002195
mg 20  9.81
 y = 0.002647 m
Additional deflection is given by relation;
e
y= 2
 n 
  −1
  
0.0003
 0.002647 = 2
 NC 
 N  −1
 
2
 638.4 
  = 1  0.11334
 N 
(On considering + Sign)
2
 638.4 
  = 1.11334
 N1 
 N1 = 605.033 rpm
(On considering – Sign)
2
 638.4 
  =1 – 0.11334 = 0.88666
 N2 
 N2 = 677.98 rpm
Thus, the range of unsafe speed is from 605.033 rpm to 677.98 rpm.

(c) (i) A bolted joint is used to connect two components. The combined stiffness of the two
components is twice the stiffness of the bolt. The initial tightening of the nut results in a
preload of 10 kN in the bolt. The external force of 7.5 kN creates further tension in the
bolt. The bolt is made of plain carbon steel 30C8, having tensile yield strength of 400
N/mm². There are coarse threads on the bolt. Calculate the tensile stress area of the bolt.
The factor of safety specified is 3.
Sol. (3) (c)
(i) Stiffness of connecting member = 2 (stiffness of bolt)
 Kcm = 2 Kb
Initial tightening load, Pi = 10 kN = 10000 N
External tensile load, P = 7.5 kN = 7500 N
Tensile yield strength of bolt, Syt = 400 N/mm2
FOS = 3 PAGE
Tensile stress area of bolt (Ab) = ? 16

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 MECHANICAL Engineering — (Paper-II)
Stiffness correction factor(C),
Kb
C=
K b + K cm
Kb
C=
K b + 2K b
1
C=
3
Total tensile force on bolt (Pb)
Pb = Pi + CP
1
 Pi = 10000 +  7500
3
 PC = 12500 N
Tensile stress on bolt (t)
Pi
t =
Ab

12500
 t =
Ab
Now,
Syt
t =
FOS
12500 400
 =
Ab 3

 A b = 93.75 mm 2

(ii) An oil ring of a shaft transmitting power is shown in the figure. There is no hydrodynamic
action over 5 mm width of the oil ring. The total radial load on the journal is 21 kN and
the journal rotates at 1440 r.p.m.
c h
= 0.8  10 −3 ; 0 = 0.2
r c
where c = radial clearance, r = radius and ho = minimum oil thickness.
For the instant case, Sommerfeld number (S) = 0.0446.
For this case, calculate the viscosity of lubricant:

PAGE
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 MECHANICAL Engineering — (Paper-II)
Sol. (3) (c)
(ii)
Radial load, W = 21 kN = 21000 N
Speed, N = 1440 rpm
c
= 0.8  10 −3
r
ho
= 0.2
c
S = 0.0446
Viscosity of lubricant, z = ?
From figure,
Length of bearing in which hydrodynamic action is occurring,
L = 60 + 60 = 120 mm = 0.12 m
Diameter of shaft/journal, d = 60 mm = 0.06 m
Now,
 zn   r 
2

S =  s   ..........(i)
 p  c 
here,
ns = speed of shaft in rps
N 1440
 ns = =
60 60
 ns = 24 rps
p = bearing pressure
W
p=
Ld
21000
p=
0.12  0.06
 P = 2916666.667 Pa
r 1
=
c c/r
r 1
 =
c 0.8  10−3
r
 = 1250
c
From equation (i)
z  24
0.0446 =  (1250)
2

2916666.667
0.0446  2916666.667
z=
24  (1250)
2

PAGE
 z = 3.469  10−3 Pa − s 18

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 MECHANICAL Engineering — (Paper-II)
Q.4. (a)
A thick cylinder of 225 mm internal diameter has to be designed for a safe internal pressure of
50 MPa. Calculate the thickness of the cylinder wall using maximum shear stress theory. The
axial stress may be neglected in the calculation. The yield stress of the cylinder material is 260
MPa and the factor of safety is 2.
Sol. (4) (a) Internal diameter, Di = 225 mm
Di 225
Internal radius, Ri = = = 112.5 mm
2 2
Internal pressure pi = 50 MPa
Axial stress, a  0 (neglecting)
yield stress, y = 260 MPa
FOS = 2
Thickness, t =?

As per Lami’s theorem

B
c = + A..............(i)
r2
B
r = − + A..............(ii)
r2
at r = r0  p = p0=0, from equation (ii)
B
0=− +A
r02

 B = Ar02 ...........(iii)
at r = ri  r = −pi, from equation (ii)
B
− pi = − +A
ri2
From equation (iii)
−Ar02
− pi = +A
ri2

 r2 − r2 
 −pi = −A  0 2 i  ………. (iv)
 ri 
Put value of A in equation (ii),
PAGE
B = Ar02 19

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 MECHANICAL Engineering — (Paper-II)
pi ri2 r02
B= ......(v)
r02 − ri2
Put value of A and B in equation (i) and (ii)
from equation (i)
pi ri2 r02 pi ri2
c = +
(r2
0 − ri2 ) r 2 r02 − ri2

pi ri2  r0 2 
c =   + 1 ………. (vi)
r0 2 − ri2  r  
from equation (vi)  c is positive and as r increases  c decreases as shown in figure
From equation (ii)
−pi ri2 r02 pi ri2
r = +
(r2
0 − ri2 ) r 2 r02 − ri2

−pi ri2  ro 2 
 r =   − 1 …….. (vii)
r02 − ri2  r  
from equation (vii) r is negative and as r increase, | r | decrease as shown in figure
At r = ri, c = ci is maximum in tensile nature and r = ri is maximum in compression
therefore shear stress will be maximum at r = ri.
From equation (vi) at r = ri

p r2  r  2 
ci = 2 i i 2  o  + 1
r0 − ri  ri  

pi ri2 r02 + ri2 

ci =  
r02 − ri2  ri2 

 r2 + r2 
ci = pi  02 i2 
 r0 − ri 
at r = ri,  ri = –pi (already known)
 Maximum shear stress (max)
ci − ri
max =
2

 r2 + r2 
pi  02 i2  − (−pi )
r −r
max = 0 i 
2

pi r02
max =
r02 − ri2 PAGE
As per maximum shear stress theory 20

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 MECHANICAL Engineering — (Paper-II)
0.5  y
max =
FOS
pi r02 0.5  260
 =
r0 − ri
2 2
2

50  r02
 = 65
r − 112.52
2
0

 50r02 = 65r02 − 822656.25

 15r02 = 822656.25

 r02 = 54843.75
 r0 = 234.187mm
thickness of cylinder (t)
t = r 0 – ri
 t = 234.187 – 112.5
 t = 121.687 mm

(b) A riveting machine is driven by a motor of 4 kW. The actual time to complete one riveting
operation is 1.5 seconds and it absorbs 12 kN-m of energy. The moving parts including
the flywheel are equivalent to 220 kg at 0.5 m radius. Determine the speed of the flywheel
immediately after riveting, if it is 380 r.p.m. before riveting. Also determine the number
of rivets closed per minute.
Sol. 4. (b)
P = 4000 W
Erequired/riveting = 12000 J
Exact punching time = 1.5 sec.
m = 220 kg
r = 0.5 m
I = mr2 = 220 × 0.52 = 55 kg.m2
ωmax = 380 rpm, ωmin = ?
No. of cycle/minute =?

Motor supplies the total energy during entire cycle uniformly;

Power × time period = Erequired/cycle
 4000 × t = 12000
 t = 3sec
PAGE
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 MECHANICAL Engineering — (Paper-II)
60
No. of cycle/minute  = 20 cycle/minute
3
Therefore, 20 rivets will be closed per minute.
Eavailable by motor in 1.5 sec  4000 × 1.5 = 6000 J
Emax = Erequired – Eavailable in 1.5 sec by motor
 Emax = 12000 – 6000 = 6000 J
Maximum fluctuation of energy is given as;

Emax = I (2max − min )

1 2

2
 2 
2

 6000 =  55   (380 2 − N min )

1 2

2  
60

 N min = 352.85 rpm

(c) Refer to the following figure of the drum brake.
Prove that the braking torque (Tf) can be expressed as
Tf = P2R(e-1) and Tf = bR2 pmax (1–e-μα)
where R drum radius, b width, p = pressure at any point in the arc of contact and P =
tensile force in the band at the same point:

Sol. 4. (c) FBD of drum for strip

PAGE
Figure (a) 22

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 MECHANICAL Engineering — (Paper-II)
FBD of band for strip

Figure (b)
P → tension in band at 
P + dP → tension in band at  + d
Normal force on strip (dN)
dN = P × area of strip
 dN = p × dA
 dN = p × Rd∅ × b …………(i)
In FBD of band
F x' =o

d  d 
Pcos + dN − (p + dP) cos   = 0
2 2
  d  
cos  2   1
   
 P + 𝜇dN – (P + dP) = 0
 P + 𝜇dN – (P – dP) = 0
 dP = 𝜇dN ………….. (ii)
and
F y 'i =0

d d
dN − P sin − (P + dP) sin =0
2 2
 d d
sin 2  2 
 
pd pd dpd dpd 
 dN − − − = 0  0
2 2 2  2 
 dN – Pd = 0 PAGE
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 MECHANICAL Engineering — (Paper-II)
 dN – Pd …………. (iii)
Put dN = Pd from equation (iii) to (ii)
dP = 𝜇 × Pd
dP
= d 
P
Integrating for contact region between band and drum
P1 dP 
P2 P
=  d 
0

 ln PP1 −  0

P 
2

P1
 ln = 
P2
P1
 = e ……...(iv)
P2
From equation (iv)
e >   P1 > P2
Therefore P1 = Pmax = tight side tension and, P2 = Pmin = stack side tension
Put dN = Pd from equation (iii) to (i)
Pd = p × Rd×b
P
p= ……...(v)
Rb
 p  P, therefore p = pmax = Maximum pressure
when P = Pmax = P1 = maximum tension from equation (v)
P1
p max = …….. (vi)
rb
From FBD of drum (figure a) braking torque on strip (dTf)
dTf = 𝜇dN × R ……… (vii)
from equation (ii) put 𝜇dN = dP in equation (vii)
dTf = dP × R
Total braking torque (Tf)
P1
Tf =  dP  R
P2

 Tf = PP1  R
P
2

 Tf = (P1 − P2 )  R ….. (viii)

 P1  
 =e 
P2 

 TF = P2 R (e − 1) First relation proved

PAGE
From equation (viii)
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 MECHANICAL Engineering — (Paper-II)
TF = (P1 – P2) R
 P 
 Tf = P1 1 − 2  R
 P1 
 P1 P 
 = e  2 = e− 
 P2 P1 
 P1 
pmax = Rb  P1 = pmax Rb
 
Tf = p max  Rb 1 − e −  R

 Tf = bR 2 p max (1 − e − ) Hence second relation proved

SECTION-B
Q.5. (a) Zirconium has an HCP crystal structure and a density of 6.51 g/cm³. The atomic weight
of zirconium is 91.22 g/mol. Answer the following:
(i) What is the volume of its unit cell in cubic metres?
(ii) If the c/a ratio is 1.593, compute the values of c and a.
Sol. (a) (i) The volume of the Zr unit cell may be computed using Equation
nA Zr
VC =
NA
Now, for HCP, n = 6 atoms/unit cell, and for Zr, AZr = 91.22 g/mol. Thus,
(6 atoms/unit cell) (91.22 g/mol)
VC =
(6.51 g/cm3 ) (6.022  1023 atoms/mol)
= 1.396 × 10–22 cm3/unit cell = 1.396 × 10–28 m3/unit cell
(ii) The solution for HCP
VC = 6R 2c 3
But, since a = 2R, (i.e., R = a/2) then
2
a 3 3a 2 c
VC = 6   c 3 =
 2 2
But, since c = 1.593a
3 3(1.593)a 3
VC = = 1.396 10–22 cm3 /unit cell
2
Now, solving for a
1/3
(2) (1.396  10−22 cm3 ) 
a= 
 (3) ( 3) (1.593) 
= 3.23 × 10–8 cm = 0.323 nm
And finally
c = 1.593a = (1.593) (0.323 nm) = 0.515 nm
(b) Give at least four comparisons between honing and lapping. Also list at least three
PAGE
functions performed by electrolyte in electrochemical machining (ECM) process.
25

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 MECHANICAL Engineering — (Paper-II)
Sol. (b) 1. Purpose and Application:
• Honing: Used to improve the geometric form of a surface and to provide a
precise surface finish. This process is often used for internal cylindrical
surfaces such as automobile engine cylinders and hydraulic cylinders.
• Lapping: Primarily aimed at achieving a highly finished surface, with
extremely tight tolerances for flatness or roundness. It is typically employed
for finishing the surfaces of, metal seals, and fine mechanical bearings.
2. Tooling and Abrasives:
• Honing: Utilizes a set of abrasive stones or sticks mounted on a tool that
rotates and moves back and forth over the workpiece. The abrasives are often
made of aluminum oxide or silicon carbide.
• Lapping: Employs a lapping plate and loose abrasive grains that are rolled
or rubbed against the workpiece, along with a lapping compound. The
abrasives may include aluminum oxide, silicon carbide, diamond dust, or
other specialized materials.
3. Surface Contact:
• Honing: The abrasive stones are in continuous contact with the workpiece,
applying a controlled amount of pressure to create the desired surface.
• Lapping: The abrasives are loosely held and the contact is less direct, with
the paste or slurry allowing the grains to move freely for a gentler and more
diffuse finishing process.
4. Process Characteristics:
• Honing: Produces a cross-hatched surface pattern that helps in retaining
lubrication, which is ideal for engine cylinders or components where
lubrication retention is crucial.
• Lapping: Yields a mirror-like finish with very high precision, which is
essential for applications demanding minimal surface irregularities and high
dimensional accuracy.
Functions of Electrolyte in Electrochemical Machining (ECM) Process:
1. Conducting Electricity:
• The electrolyte acts as a conductor for the electric current between the tool
(cathode) and the workpiece (anode). This is crucial for initiating and
sustaining the electrochemical reaction necessary for material removal.
2. Removing Material:
• As the electric current passes through the electrolyte, it facilitates the removal
of metal from the workpiece through an electrochemical process. The metal
atoms at the workpiece surface lose electrons (oxidize) and dissolve into the
electrolyte. PAGE
26

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 MECHANICAL Engineering — (Paper-II)
3. Cooling the Tool and the Workpiece:
• During the ECM process, heat is generated due to the electrical resistance and
chemical reactions. The electrolyte helps in dissipating this heat, thereby
cooling both the tool and the workpiece. This prevents thermal damage and
maintains the integrity of the machined surface.
(c) List five causes of service failure giving example of at least one mechanical component
in which it occurs. Also list at least five causes of vibration in mechanical system.
An automobile has four tyres. The constant failure rates of tyres 1, 2, 3 and 4 are 0.00001
failure/hour, 0.00002 failure/hour, 0.00003 failure/hour and 0.00003 failure/hour
respectively. The automobile cannot be driven when any one of the tyres punctures. Find
the mean time to failure of the automobile with respect to tyres and reliability for
operating the automobile for 500 hours without failure of tyres.
Sol. (c) Fatigue:
Example: Crankshaft in an engine
Description: Repeated loading and unloading cycles cause small cracks to develop and
propagate over time, leading to eventual failure.
Wear:
Example: Bearings in a rotary machine
Description: Continuous friction between surfaces causes material loss, leading to
increased clearance and eventual malfunction.
Corrosion:
Example: Pipeline in a chemical plant
Description: Chemical reactions with the environment cause the metal to deteriorate,
weakening the structure and causing leaks or bursts.
Overloading:
Example: Gear in a transmission system
Description: Operating under excessive load beyond the designed capacity leads to
deformation or breakage of the gear teeth.
Material Defects:
Example: Turbine blade in a jet engine
Description: Inherent flaws in the material, such as inclusions or voids, can lead to
unexpected failure under operational stresses. Causes of Vibration in Mechanical
Systems:
Unbalanced Rotating Components:
Description: When the mass distribution is not even around the axis of rotation, it causes
periodic forces leading to vibration.
Misalignment:
Description: Shafts or other components that are not aligned properly can induce lateral
PAGE
or axial vibrations. 27

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 MECHANICAL Engineering — (Paper-II)
Loose or Worn Components:
Description: Parts that are not securely fastened or are worn out can move irregularly,
causing vibrations.

Resonance:
Description: When the natural frequency of a system coincides with the operating
frequency, it can lead to amplified vibrations.
Gear Defects:
Description: Issues such as worn teeth, incorrect gear meshing, or damaged gears can
cause uneven torque transmission and vibrations.

Bearing Defects:
Description: Faulty bearings can lead to irregular motion and cause vibrations due to the
uneven movement of the rotating parts
Calculation of Mean time to failure (MTTF)
For a series system, the overall failure rate  is the sum of the individual failure rates:
 =  1 + 2 + 3 + 4
= 0.00001 + 0.00002 + 0.00003 + 0.0003 = 0.00009 failures/hr
The mean time to failure is the reciprocal of the failure rate:
1 1
MTTF = = = 11111.11 hrs
 0.00009
Calculation of reliability for 500 hours.
R(t) = e–t
For t = 500 hours
R(500) = e–0.00009 × 500 = 95.56%
(d) You are a consultant for operations of a firm that deals with just one item that costs ₹45.
The firm buys the item wholesale from a supplier and sells retail. You have compiled the
following details for the item:
Parameters Values
Annual demand 4380
Workdays/year 365
Opportunity cost of investment in inventory 12.5%
Fixed cost of order generation per order ₹22
Cost of inspecting items received ₹3
Cost due to breakage or spoilage 9.5%
Warehouse rental 6.5%
Insurance costs 1.5%
The following two options are available to you:
Option 1: The supplier can supply all items at once
Option 2: The supplier can supply 15 items per day
PAGE
Which of the options would you recommend to the firm and why?
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 MECHANICAL Engineering — (Paper-II)
Sol. (d) Find the holding cost (CH)
CH = Unit cost × (opportunity cost + warehouse rental + insurance)
CH = 45 (12.5% + 9.5% + 1.5%) = ₹10.575
Option 1 (Single order)
Order cost = Fixed order generation + inspecting (O.C) = 22 + 22 = ₹44
Holding cost = 2190 × 10.575 = ₹23159.25 (H.C)
Breakage/spoilage cost 4380 × 3 = 13140
Total cost = O.C + H.C + Breakage
= 44 + 23159.25 + 13140 = ₹36343.25
Option 2 (Daily supply of 15 items)
4380
Daily demand =  12 unit / day
365
Order frequency → Daily so no holding cost
Order cost = 44 × 365 = 16060
Breakage = 4380 × 3 = 13140
Total cost = O.C + Breakage = 16060 + 13140 = ₹29200/
Conclusion: Option 2 is recommended due to significantly lower total cost.
(e) Compare between hydraulic and electrical actuators' characteristics in the following
points in brief:
(i) Stiffness of the actuators
(ii) Need of reduction gear
(iii) Need of braking device
(iv) Working in low and high temperature
(v) Working of the actuators
(vi) Maintenance need of the actuators
Sol. (e) (i) Stiffness of the Actuators
• Hydraulic Actuators: Tend to have high stiffness due to the
incompressibility of the hydraulic fluid. The system's inherent rigidity makes
it well-suited for applications requiring precise control under high load
conditions.
• Electrical Actuators: Generally have lower stiffness compared to hydraulic
actuators. The elasticity of mechanical components like gears and belts can
introduce some play and flexibility, which might be a drawback in
applications demanding high precision.
(ii) Need of Reduction Gear
• Hydraulic Actuators: Typically do not require reduction gears because they
can generate high torque at low speeds directly through hydraulic pressure.
• Electrical Actuators: Often need reduction gears to achieve high torque.
Electric motors usually operate at high rotational speeds with lower torque,
necessitating gears to reduce the speed and increase the torque to usable
levels. PAGE
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 MECHANICAL Engineering — (Paper-II)
(iii) Need of Braking Device
• Hydraulic Actuators: Often require braking devices to hold positions, as
hydraulic systems can drift if not properly sealed or if the valve control is not
precise.
• Electrical Actuators: Electric motors can inherently provide braking through
electromagnetic forces. Additionally, many electric actuators can be designed
to hold position without power by using worm gears or other self-locking
mechanisms.
(iv) Working in Low and High Temperature
• Hydraulic Actuators: Can be sensitive to temperature extremes. Low
temperatures can thicken hydraulic oil, reducing its efficiency, while high
temperatures might lead to overheating or seals failure.
• Electrical Actuators: Typically more robust across a broader range of
temperatures, especially with recent advances in materials and components.
However, at very high temperatures, insulation materials and other
components may degrade.
(v) Working of the Actuators
• Hydraulic Actuators: Work by pressurizing hydraulic fluid in a cylinder,
which creates linear or rotational motion. This process is highly effective for
generating large forces and is commonly used in heavy-duty applications.
• Electrical Actuators: Convert electrical energy into mechanical motion,
generally using rotary motors that are either converted into linear motion
through screws or belts, or used as-is for rotary applications. Suitable for
precise, clean, and quiet operations.
(vi) Maintenance Need of the Actuators
• Hydraulic Actuators: Require regular maintenance to check for leaks,
replace hydraulic fluid, and maintain seals and filters. This maintenance is
crucial for performance and longevity, and lack of it can lead to system
failure.
• Electrical Actuators: Generally have lower maintenance needs as they have
fewer moving parts and do not require fluid replacements. However, they still
need periodic inspection of electrical components and lubrication of
mechanical parts.

Q.6. (a) (i) Three jobs are to be processed in a job shop consisting of three machines. Each job
requires three operations and they are to be carried out in 1→2→3 order. The
following table indicates the machines required as well as processing time (in hours)
required for each operation. Initially, all jobs and machines are available. Compute
the make span by drawing Gantt chart indicating every operation of each job using
shortest processing time dispatching rule and break ties with least work remaining PAGE
rule: 30

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 MECHANICAL Engineering — (Paper-II)

Machine required for operation Processing time of operation

1 2 3 1 2 3
Job 1 M1 M2 M3 4 2 3
Job 2 M1 M3 M2 2 4 4
Job 3 M3 M2 M1 3 5 3
Sol. (a) (i)
Machine required for operation Processing time of operation
1 2 3 1 2 3
Job 1 M1 M2 M3 4 2 3
Job 2 M1 M3 M2 2 4 4
Job 3 M3 M2 M1 3 5 3

Make span time = 14 hours

(a) (ii) Explain the physics of arc initiation in arc welding. Why is arc initiation difficult in
plasma arc welding? Why is plasma arc welding called as plasma arc welding
despite the fact that plasma is present in all other arc welding processes?
Sol. (a) (ii) Physics of Arc Initiation in Arc Welding
Arc initiation in welding generally involves creating an electric arc between an
electrode and the workpiece. This arc is formed when a sufficiently high voltage is
applied, overcoming the dielectric breakdown of the air or shielding gas between
the electrode and the workpiece. When the breakdown occurs, it ionizes the air or
gas, turning it into a conductor which allows current to pass and heat the material to
welding temperatures.
Challenges in Arc Initiation in Plasma Arc Welding
Plasma arc welding (PAW) uses a constricted plasma jet as the heat source, which
can be initiated by either transferring an arc from a pilot arc or by direct initiation at
the torch. Here’s why it’s particularly challenging: PAGE
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 MECHANICAL Engineering — (Paper-II)
• Constricted arc: The plasma in PAW is tightly constricted by a fine-bore
copper nozzle, which raises the temperature and velocity of the plasma jet.
This constriction makes the initial ionization of the gas more difficult
compared to other forms of arc welding where the arc spreads more freely.
• Stability requirement: The stability of the pilot arc, which is crucial for
initiating the main welding arc in non-contact starts, requires precise control
over the torch setup and gas flow. This adds complexity to arc initiation.
• Shielding and plasma gas: The need to maintain precise flows and balances
between shielding gas and plasma gas further complicates the initiation
process.
Why is it called "Plasma Arc Welding"?
Plasma arc welding is named for the very distinct role plasma plays in the process.
Although all arc welding processes generate some plasma, PAW uniquely
manipulates the plasma itself as a more defined and controlled heat source.
(b) (i) Briefly describe the techniques that may be used for galvanic protection. Also
explain why cold-worked metals are more susceptible to corrosion than non-cold-
worked metals.
Sol. (b) (i) Techniques for Galvanic Protection: Galvanic protection involves using
electrochemical principles to prevent metal corrosion. Here are the primary
techniques used:
Sacrificial Anode Protection (Cathodic Protection): Principle: A more anodic
(reactive) metal is connected to the metal to be protected, which acts as the cathode.
Process: The sacrificial anode corrodes instead of the protected metal.
Application: Commonly used in marine environments, underground pipelines, and
water heaters.
Materials: Typical sacrificial anodes include zinc, magnesium, and aluminum.
Impressed Current Cathodic Protection (ICCP):
Principle: An external power source supplies current to counteract the corrosive
currents.
Process: An inert anode material is used with a direct current power source, which
provides electrons to the protected metal.
Application: Used for large structures like pipelines, ship hulls, and steel-reinforced
concrete.
Materials: Inert anodes such as titanium, mixed metal oxides, or platinum-coated
anodes.
Cold-Worked Metals and Corrosion Susceptibility
Cold-worked metals are more susceptible to corrosion compared to non-cold-
worked (annealed) metals due to the following reasons: PAGE
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 MECHANICAL Engineering — (Paper-II)
Increased Dislocation Density:
Effect: Cold working introduces a high density of dislocations and defects in the
metal’s crystal structure.
Corrosion Mechanism: These dislocations serve as pathways for corrosion,
increasing the metal’s susceptibility to localized corrosion such as pitting and stress
corrosion cracking.
Residual Stresses:
Effect: Cold working generates residual stresses within the metal.
Corrosion Mechanism: These stresses can create micro-cracks or weaken the
metal, providing sites for corrosive agents to penetrate and initiate corrosion.
Altered Microstructure:
Effect: Cold working can lead to grain refinement and introduce inhomogeneities.
Corrosion Mechanism: The altered microstructure may have regions of different
electrochemical potentials, leading to galvanic corrosion within the metal itself.
Decreased Passivity:
Effect: The passive oxide layer on metals like stainless steel can be disrupted by
cold working.
Corrosion Mechanism: The disruption of the passive layer exposes the metal to the
environment, increasing its vulnerability to corrosion.
(b) (ii) Write the possible oxidation and reduction half-reactions that occur when
magnesium is immersed in each of the following solutions:
(1) HCI
(2) HCl solution containing dissolved oxygen
(3) HCl solution containing dissolved oxygen and in addition Fe2+ ions
In which of the above solutions would you expect the magnesium to oxidize rapidly
and why?
Sol. (b) (ii) When magnesium is immersed in various solutions, different oxidation and
reduction half-reactions can occur depending on the constituents of the solution.
Here are the possible half-reactions for each scenario:
Possible Oxidation and Reduction Half-Reactions
(1) Magnesium in HCI (Hydrochloric Acid) Solution
Oxidation half-reaction (anode):
Mg (s) → Mg2+ (aq) + 2e–
Reduction half-reaction (cathode):
2H+ (aq) + 2e– → H2(g)
(2) Magnesium in HCI Solution Containing Dissolved Oxygen
Oxidation half-reaction (anode):
PAGE
Mg (s) → Mg2+ (aq) +2e– 33

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 MECHANICAL Engineering — (Paper-II)
Reduction half-reactions (cathode):
• For hydrogen ions:
2H+ (aq) + 2e– → H2(g)
• For dissolved oxygen:
O2(g) + 4H+ (aq) + 4e– → 2H2O(1)
(3) Magnesium in HCI Solution Containing Dissolved Oxygen and Fe2 + Ions
Oxidation half-reaction (anode):
Mg (s) → Mg2+ (aq) + 2e–
Reduction half-reactions (cathode):
• For hydrogen ions:
2H+ (aq)+ 2e– → H2(g)
• For dissolved oxygen:
O2(g) + 4H+ (aq) + 4e– 2H2O(1)
• For iron(II) ions:
Fe3+ (aq) + e– → Fe2+(aq)
Magnesium would oxidize most rapidly in the HCl solution containing dissolved
oxygen and Fe2+ ions. This is because:
(i) Multiple Reduction Reactions: The presence of multiple reduction reactions
(hydrogen ion reduction, oxygen reduction, and Fe3+ reduction) provides
several pathways for the consumption of electrons. This enhances the overall
corrosion rate of magnesium.
(ii) Dissolved Oxygen: Dissolved oxygen is a strong oxidizing agent, which can
significantly accelerate the corrosion process through the reduction of
oxygen, thereby increasing the rate of magnesium oxidation.
(iii) Presence of Fe2+ Ions: The presence of Fe2+ ions further accelerates the
process because Fe3+ ions can be reduced to Fe2+, providing an additional
reduction reaction that consumes electrons, thus enhancing the oxidation of
magnesium.
In summary, the HCl solution containing dissolved oxygen and Fe2+ ions creates an
environment with multiple active reduction reactions, which collectively increase
the rate of electron consumption, leading to a more rapid oxidation of magnesium.
(c) (i) The forward kinematic model of a planar 2 DOF (RR) manipulator with link lengths
a1 = a2 = 10 units, is given by the matrix
0 −1 0 10 / 2 
 
1 0 0 10 + 10 / 2
o
T2 =  
0 0 1 0 
0 0 
 0 1 
Draw the last frame {2}, with respect to {0} frame, by locating its position and its PAGE
orientation. The initial frame, frame {0} is given as 34

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 MECHANICAL Engineering — (Paper-II)

Sol. (c) (i) a1 = a2 = 10 units

 Rotation indicate a 90° counterclockwise rotation about z-axis.

 10 10 
 Translation is  ,10 + 
 2 2
Frame {2}
10
Start from origin O0 of frame {0} moving along the original x-axis by units and
2
10
then parallel to the original y-axis by 10 + units .
2

(c) (ii) For the given frames of SCARA manipulator, generate the DH parameters table:

PAGE
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 MECHANICAL Engineering — (Paper-II)
Sol. (c) (ii)

I → Angle between the previous z-axis and the current z-axis, about the previous
x-axis.
di → The offset along the previous z-axis to the common normal.
ai → The length of the common normal.
I → Angle between the previous x-axis and the current x-axis, about the common
normal.
i = 1, 2, 3, 4.
DH Parameters table
Joint i i di ai i (degree)
1 1 0 L11 0
2 2 0 L12 0
3 0 d3 0 0
4 4 L4 0 0
Q.7. (a) (i) How does permeability of molding sand vary with the moisture content? Explain
with the help of neat sketches. Also explain the role of adding organic additives in
the molding sand.
Sol. (a) (i) Permeability: Gases are formed due to mould metal reaction and also due to
vapourization. The mould must be porous to permit the gases to pass off, otherwise
will have gas holes defect. If the grain size of sand is large, there will be larger void
size between particles. This leads to larger permeability.

PAGE
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 MECHANICAL Engineering — (Paper-II)
As shown is figure if the water content is less, these voids will be filled with smaller
sand particles which results in lower permeability. By increasing the water content,
smaller sand particles are also combine together, this increase permeability. Once
the percentage of water goes beyond 8%, water start accumulating in these voids
and the sand becomes pasty. This decreases permeability and decrease in strength of
the mould. Permeability is quantified by Permeability Number (PN) which is
defined as
VH
PN =
PAT
PN is the ratio in millimeters at which air will pass through the sand under a standard
condition of pressure.
Role of Additives
• Cereal binder up to 2% increases the strength.
• Pitch if used up to 3% would improve the hot strength.
• Saw dust up to 2% may improve the collapsibility by slowly burning and increase
the permeability.
• Other materials: Sea Coal, Asphalt, Fuel Oil, Graphite, Molasses, Iron oxide, etc.

(a) (ii) A dimension 57.975 mm is required to be set with the help of slip gauge blocks as
accurately as possible. Two slip gauge block sets M45 (Grade 0) and M112
(Grade II) are available. The range and number of pieces in each set are given below:
Set M45 (Grade 0) Set M112 (Grade II)
Range Steps Number of Range Steps Number of
(mm) (mm) blocks (mm) (mm) blocks
1.001 to 0.001 9 1.0005 – 1
1.009
1.01 to 1.09 0.01 9 1.001 to 0.001 9
1.009
1.1 to 1.9 0.1 9 1.01 to 1.49 0.01 49
1.0 to 9.0 1.0 9 0.5 to 24.5 0.5 49
10.0 to 90.0 10.0 9 25.0 to 25.0 4
100.0
The permissible errors in 1/100000 mm units in the mean length of Grade 0 and Grade II
are given below:
Length 0 to 20 20 to 60
Grade II +50 +80
–20 –50
Grade 0 10 15
Find the slip gauge that you will prefer, with reasons. PAGE
37

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 MECHANICAL Engineering — (Paper-II)
Sol. (a) (ii) For more accuracy we will chose grade ‘0’ as the tolerance build as will be less

Grade 0 Grade II

Tolerance build up

Tolerance build up +50  3 + 80 = +230

 Width of tolerance
= 4 × 10 + 15 = ± 55 −20  3 − 50 = −110

(110) width of tolerance zone

(b) (i) It is possible to drill a 25 mm nominal hole to an accuracy of 25+−0.02

0.02 mm using

standard drill and drilling machine available. A shaft is to be machined to obtain a

clearance fit in the above hole such that minimum allowance should be 0.01 mm
and maximum clearance should not be more than 0.07 mm. Find the tolerance on
the shaft. Also state why hole basis system of fits is generally preferred over shaft
basis system of fits.

Sol. (b) (i)

Minimum Hole Size = 25 − 0.02 = 24.98 mm

Maximum Hole Size = 25 + 0.02 = 25.02 mm
Minimum Allowance = 0.01 mm
Maximum Clearance = 0.07 mm
Maximum Shaft Size = 24.98 mm − 0.01 mm = 24.97 mm
Minimum Shaft Size = 25.02 mm − 0.07 mm = 24.95 mm
The tolerance on the shaft is = 24.97 − 24.95 = 0.02 mm
Reason for Preference of Hole Basis System:
• Manufacturing Convenience: Holes are generally easier to control in terms
of size during manufacturing processes, especially when drilling, reaming, or
boring. This is because the tools for creating holes tend to have standardized
PAGE
sizes.
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 MECHANICAL Engineering — (Paper-II)
• Tooling Costs: Standardized hole sizes mean that tools and gauges are readily
available and less expensive compared to custom sizes required for shaft basis
systems.
• Interchangeability: With a hole basis system, a variety of shaft sizes can be
used with a single hole size, improving interchangeability and reducing
inventory costs.
• Machining Consistency: It is often easier to maintain consistency in hole
sizes because machining operations like drilling and reaming produce more
uniform results compared to turning operations used for shafts.
(b) (ii) List the manufacturing situations where FMS technology can be successfully
employed. Also give at least four differences between dedicated and random-order
FMS.
Sol. (b) (ii) Situations for Successful Employment of FMS:
1. Variable Product Mix: FMS is ideal in environments where the product mix
changes frequently, requiring the manufacturing process to adapt quickly
without significant downtime.
2. Moderate Volume, High Variety: FMS systems excel in situations where
the production volume is not high enough to justify dedicated assembly lines,
but the variety of products demands flexibility in production capabilities.
3. Custom Manufacturing: Companies that offer customized or bespoke
products can benefit from FMS due to its ability to switch between different
product designs quickly.
4. Just-In-Time Manufacturing: FMS supports JIT manufacturing practices
by reducing setup times and enabling efficient response to production
demands without the need for large inventories.
5. Complex Machining Tasks: Industries requiring complex, precise
machining tasks (like aerospace or medical devices) find FMS valuable
because of its precision and repeatability across diverse tasks.
Differences Between Dedicated and Random-Order FMS:
1. Flexibility in Operation:
• Dedicated FMS: Configured to produce a specific range of parts or
products, with limited flexibility. It is optimized for a particular set of
similar operations or products.
• Random-Order FMS: Designed to handle any order of products
within a mix at any time, providing higher flexibility and the ability to
adapt to changing production requirements quickly.
2. System Layout:
• Dedicated FMS: Typically has a fixed layout optimized for the
efficient production of a particular set of products.
• Random-Order FMS: Features a more dynamic layout that can be
adjusted based on the production schedule and is not tied to a specific PAGE
sequence of operations. 39

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 MECHANICAL Engineering — (Paper-II)
3. Production Capacity and Scalability:
• Dedicated FMS: Generally has higher production capacity for specific
products but is less scalable since adapting to new products may require
significant reconfiguration or additional investment.
• Random-Order FMS: More scalable in terms of handling various
products as market demands shift, though it might operate with less
operational efficiency compared to a perfectly tuned dedicated system.
4. Capital Investment and Operating Costs:
• Dedicated FMS: Might involve lower initial capital investment for
specific product lines but can incur higher costs if product
specifications change significantly.
• Random-Order FMS: Requires a higher initial investment due to the
need for more sophisticated control systems and equipment that can
accommodate a wide variety of products, but potentially lower long-
term costs by avoiding the need for future significant investments.
5. Typical Applications:
• Dedicated FMS: Best suited for stable product demands with little
variation in type and design, such as automotive or electronic
component manufacturing.
• Random-Order FMS: Ideal for industries like consumer electronics
or furniture where product designs and demands can change rapidly
and unpredictably.
(c) Formulate the forward kinematic model of the 3 DOF (RPP) manipulator arm, shown in the
figure, by
(i) generating and drawing the frames using DH rules;
(ii) generating the DH parameters table from the assigned frames;
(iii) generating the individual transformation matrices 0T1, 1T2, 2T3 and the overall
transformation matrix 0T3.
Also draw the last frame {3}, if 1, d2 and d3 are given respectively as 0°, 10 units and 10
units, with reference to the given initial frame:

PAGE
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 MECHANICAL Engineering — (Paper-II)
The homogeneous transformation matrix i-1Ti is given as
ci −si c i −s  i s  i  i ci 
 
i −1 si −ci c i −ci s i  i s i 
Ti = 
0 s i c i d i 
 0 0 0 1 

Sol. (c) (i) • Joint 1 (Revolute): Rotates around z-axis, joint 2 prismatic. Extends along
the y-axis and joint 3 (Prismatic): Extends along the y-axis.
Frames:
• Frame 0: At the base, with z0 up, frame 1: located at joint 1, rotates with it
frame 2: located at the base of joint 2, extends in y-axis and frame 3: located
at the base of joint 3, extends in y-axis.
Drewing Frames:
• For joint 1: x1 along y0, z1 aligned with z0.
For joint 2: x2 along x1, z2 along y1
For joint 3: x3 along y2, x3 along y2.
DH Parameters
Joint  d a 
1 1 0 0 90°
2 0 d2 0 0
3 0 d3 0 0
Individual and overall transformation matrixes.
0
T1 for joint 1:
cos 1 – sin 1 0 0
 
sin 1 cos 1 0 0
0
T1 = 
 0 0 1 0
 0 0 0 1
1
T2 for joint 2:
1 0 0 0
 
0 1 0 0
1
T2 = 
0 0 1 d 2 
0 0 0 1
2
T3 for joint 3:
1 0 0 0
 
0 1 0 0
2
T3 = 
0 0 1 d 3
0 0 0 1
Overall transformation at matrix 0T3 PAGE
0 0 1
T3 = T1 × T2 × T3 2 41

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 MECHANICAL Engineering — (Paper-II)

cos 1 − sin 1 0 − sin 1 d 2

 
sin 1 cos 1 0 cos 1 (d1 + d 2 )
= 
 0 0 1 0 
 0 0 0 1 

Q.8. (a) A 12.7 mm diameter steel wire is drawn to obtain 35.5% reduction in area by drawing
through a conical die of 6º semi-cone angle. The coefficient of friction between the wire
material and die material at conical portion of die is 0.1 and there is no back pull. The
tensile yield strength of the original specimen is 207 MPa and is 414 MPa at a strain of
0.5. Assuming linear stress relationship for the wire material and efficiency of electrical
motor as 98%, find the drawing power and maximum possible reduction.
 
Sol. (a) Given, di = 12.7 mm,  = 6°, Ao =  d i2 =  12.7 2 = 126.67 mm 2
4 4
Af = 0.645 × Ai
= 0.645 × 126.67
= 81.70 mm2
Stress-strain relationship is linear
414 − 207
 yf = 207 +  0.438 = 388 N/mm 2
0.5
Ai 126.67 
 = ln = ln   = 0.438
Af  81.70 

B =  cot  = 0.1 cot 6° = 0.95

207 + 388
o = = 297.5 MPa
2

1 + B    A f 
B
d = o   1 − 
 B    Ai  

1 + 0.95    81.70  
0.95
 297.5 =   1 −   
 0.95   126.67  
1.95 
= 297.5  1 − (0.64) 
0.95
0.95
= 610.65 [1 – 0.65]
= 211.57 MPa
For power, Assume v = 1 m/s
d  v  A f 211.57  1  81.70
P=  = 17.63 kW
0.98 0.98
Maximum possible reduction
d = o (for maximum reduction)
PAGE
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 MECHANICAL Engineering — (Paper-II)

 0.95 + 1   A f 
0.95 
1=   1 − 
 0.95    Ai  
0.95
A 
0.487 = 1 −  f 
 Ai 
0.95
A 
0.512 =  f 
 Ai 
Af
0.4942 =
Ai

 A − Af 
% reduction =  i   100 = (1 − 0.4942)  100 = 50.57%
 Ai 
(b) (i) The transformation of frame {i-1} to frame {i} consists of four basic transformations
as following:
(1) A rotation about Zi-1 axis by an angle i
(2) A translation along Zi-1 axis by distance di
(3) A translation along Xi axis by distance ai
(4) A rotation about Xi axis by an angle i
Generate the individual transformation matrices and also the composite
transformation matrix i–1Ti, due to the above successive transformations. If all the
above parameters (DH) are zero, what will be the composite transformation matrix?
Sol. (b) (i) Transformation matrices for moving from frame i-1 to frame i using DH convection.
Determine the composite transformation matrix when all parameter are zero.
(1) Rotation about Zi-1 axis by angle i
cos i sin i 0 0
 
sin i cos i 0 0
R = 
 0 0 1 0
 0 0 0 1

(2) Translation along Zi-1 axis by distance di

1 0 0 0
 
0 1 0 0
Td = 
0 0 1 d i 
0 0 0 1 

(3) Translation along Xi axis by distance ai

1 0 0 ai
 
0 1 0 0
Ta = 
0 0 1 0 
PAGE
0 0 0 1  43

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 MECHANICAL Engineering — (Paper-II)
(4) Rotation about Xi axis by angle i

1 0 0 0
 
0 cos i sin i 0
R = 
0 sin i cos i 0
0 0 0 1

Composite transformation matrix

Tii −1 = R   Td  Ta  R 

The individual matrix for zero parameters are

1 0 0 0
 
0 1 0 0
R  = R  = Td =  = 
0 0 1 0
0 0 0 1

1 0 0 0
 
i −1 0 1 0 0
Ti = 
0 0 1 0
0 0 0 1

(b) (ii) Explain the following sensor characteristics in brief:

(1) Range (2) Resolution
(3) Reliability (4) Repeatability
(5) Sensitivity
Sol. (b) (ii) (i) Range: The range of a sensor refers to the span of input values that it can
accurately measure.
Example: If a temperature sensor has a range of -50°C to 150°C, it means it
can accurately measure temperatures within that interval.
(ii) Resolution: Resolution is the smallest change in the measured quantity that
the sensor can detect.
Example: If a pressure sensor has a resolution of 0.1 psi, it means it can detect
changes in pressure as small as 0.1 psi.
(iii) Reliability: Reliability indicates the sensor's ability to perform consistently
under specified conditions over time.
Example: A reliable sensor will consistently produce accurate readings
without frequent failure or need for recalibration.
(iv) Repeatability: Repeatability refers to the sensor’s ability to produce the same
output for the same input when measured multiple times under the same
conditions.
Example: If a sensor repeatedly measures a weight of 100 grams as 100
grams in multiple trials, it has high repeatability. PAGE
44

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 MECHANICAL Engineering — (Paper-II)
(v) Sensitivity: Sensitivity is the ratio of the change in output to the change in
input. It indicates how much the sensor's output will change in response to a
change in the measured quantity.
Example: If a sensor’s output changes by 5 units for every 1 unit change in
input, the sensitivity is 5 units per unit of input.

(c) (i) Generate a forward kinematic model of the given two degrees of freedom (RP)
planar manipulator.
Sol. (c) (i) By using Denovit-Hartenberg parameter method.
1st Joint 1 (Revolute joint) → Rotates about z-axis
Jiont 2 (Prismatic joint) → Extends along x-axis
nd
2 Frame 0: Fixed at the base of the manupulator.
The z-axis is along the axis of the rotation of the first joint.
Frame 1: Aligned with frame 0 initially but rotates about the z-axis of frame
based on the joint angle 1.
Frame 2: Located at the end of the prismatic joint, translates along the x-axis
of frame 1 by distance d2.
DH Parameter
i → Angle about the previous z-axis to the current z-axis.
di → Offset along the previous z-axis to the common normal.
ai → Length of the common normal.
i → Angle about common normal from the previous z-axis.
Joint i i di ai i
1 1 0 0 0
2 0 d2 0 0
Transformation matrices
(a) Transformation from frame 0 to frame 1 (T10)
cos 1 sin 1 0 0
 
0 
sin 1 cos 1 0 0
T1 = 
 0 0 1 0
 0 0 0 1
(b) Transformation from frame 1 to frame 2 (T21)
1 0 0 d2
 
1 
0 1 0 0
T1 = 
0 0 1 0 
0 0 0 1 

T20 = T10  T21 PAGE

45

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 MECHANICAL Engineering — (Paper-II)

cos 1 sin 1 0 d 2 cos 1

 
sin 1 cos 1 0 d 2 sin 1 
=
 0 0 1 0 
 0 0 0 1 

(c) (ii) Determine the joint variables (1, d2) for the above manipulator using inverse
kinematic model, if the position and orientation of the end-effector are given by the
following matrix:
0.707 0 70.71 
0.707
 
0.707 0 −0.707 −70.71
TE = 
 0 1 0 0 
 0 0 0 1 

Given that
ci −si c i si s i a i ci 
 
i −1 si ci c i −ci s i a i s i 
Ti = 
0 s i c i d i 
 0 0 0 1 

−0.707 0 −0.707 −70.71

 
 0.707 0 −0.707 0 
Sol. (c) (ii) TE = 
 0 1 0 1 
 0 0 0 1 
From matrix the position vector = (Px, Py, Pz) = (–70.70, 0, 1)
 0.707 
1 = tan −1  
 −0.707 
1 = 225° or –135°
−70.70
d2 = = 100 units
cos(225)
 PAGE
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