1

ACE
Engineering Academy
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IES Full Length Mock Test Offline 2014
BRANCH: Mechanical Engineering
PAPER II
(Conventional)
INSTRUCTIONS
Please read each of the following instructions carefully before
attempting questions:
Candidates should attempt FIVE questions in all.
Question No.1 is compulsory. Out of the remaining SIX
questions attempt any FOUR.
All questions carry equal marks. The number of marks carried
by a part of a question is indicated against it.
Answers must be written in ENGLISH only.
Time Allowed: Three Hours Maximum Marks : 200
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Assume suitable data, if necessary and indicate the same
clearly.
Unless otherwise mentioned, symbols and notations have their
usual standard meanings.
Assume suitable data, if necessary and indicate the same
clearly.
Neat sketches may be drawn, wherever required.
All parts and sub-parts of a question are to be attempted
together in the answer book.
Any pages left blank in the answer book must be clearly struck
out.
01.
(a) What are the requirements of static equivalence and
dynamic equivalence in single cylinder engine balancing.
(4 M)
(b) Explain the procedure for the selection of wire ropes from
manufacturers catalogue. (4 M)
(c) Explain the mechanism by which the chip formation taking
place during machining? and give the type of chips
produced during machining of soft and brittle work pieces.
(4 M)
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(d) At a point in a strained material,the principal stresses are
120 MPa tensile and 60 MPa compressive. Find the
resultant stress and its direction on a plane inclined at 45
to the axis of 120MPa stress. Also determine the maximum
intensity of shear stress in the material. (4 M)
(e) Define indexing in milling? What are the different methods
used for indexing in milling? (4 M)
(f) Explain the steps for design of muff or sleeve coupling.
(4 M)
(g) Explain how break even analysis can be used for decision
making purpose? Illustrate with figure. (4 M)
(h) Explain strain hardening process with one example? (4 M)
(i) In a four bar mechanism, S and L are the lengths of the
shortest and the longest links, P and Q are the lengths of
remaining links. State the condition for at least one link to
make a full revolution . Sketch and name the mechanism.
(4 M)
(j) What is slush casting? Give its applications? (4 M)
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02.
(a) A simply supported beam with overhanging ends carries
transverse loads as shown in figure, if W = 10w, what is
the overhanging length on each side, such that bending
moment at middle of beam is zero ? Sketch the bending
moment diagram. (10 M)
(b) An automotive single-plate clutch consists of a pair of
contacting surfaces. The inner and outer diameters of
friction plates are 120 mm and 250 mm respectively. The
coefficient of friction is 0.25 and the total axial force is 15
kN. Calculate the power transmitting capacity of the clutch
plate at 500 rpm using
(i) uniform wear theory and
(ii) uniform pressure theory. (10 M)
(c) A spring loaded Hartnell governor has arms of equal
length. The fly masses rotate in a circle of 140 mm
diameter when the sleeve is in mid position and the ball
arms are parallel to axis of governor. The equilibrium
speed for this configuration is 500 rpm neglecting friction.
The maximum sleeve displacement is 30 mm and
maximum variation of speed considering friction is 5 % of
the speed at mid position configuration. The mass of the
sleeve is 5 kg and friction is equivalent to 20 N at the
sleeve. Neglect the obliquity effects of arms.
R
B
R
A
W
W
D B
A
C
w/m
10 m
l l
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Find
(i) the value of each rotating mass
(i) spring stiffness in N/mm
(ii) initial spring compression (10 M)
(d) Which one of the three bearings listed below will you
choose to take a heavy axial load on the bearing
(i) Self aligning ball bearing
(ii) Deep groove ball bearing
(iii) Thrust Bearing.
Give reasons for your selection. (10 M)
03.
(a) A solid steel shaft is to transmit 75 kW at 200 r.p.m.
Taking allowable shear stress as 70 MPa, find suitable
diameter of the shaft, if the maximum torque transmitted in
each revolution exceeds the mean by 30%. Also find the
outer diameter whose inside diameter is 0.7 of the outside,
which can replace the solid shaft. (10 M)
(b) A 100 mm diameter shaft operating at 2000 rev/min is
supported by means of a 150 mm long full journal bearing
which is subjected to a radial load of 43 kN. Assume
6
10 30
P
N

=

.
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Determine
(i) The coefficient of friction using McKee equation which
is given by K
C
D
P
N
0.326 f +
|
.
|

\
|
|
.
|

\
|
= . Take D/C = 1000,
K = 0.002.
(ii) Bearing pressure in MN/m
2
.
(iii) Heat generated. (10 M)
(c) A machine part of mass 2 kg vibrates in a viscous medium.
Determine the damping coefficient when a harmonic
exciting force of 25N results in a resonant amplitude of
1.25 cm with a period of 0.20 seconds. If the system is
excited by a harmonic force of frequency 4 cycle/sec. What
will be the percentage increase in the amplitude of forced
vibration when damper is removed. ? (10 M)
(d) A cantilever beam with the triangular cross-section shown
in fig carries a uniformly distributed load of intensity
2 kN/m over its entire length. If the depth h of the cross-
section is twice its base b, and if the allowable tensile or
compressive stress is 24 MPa, determine the minimum
dimensions the cross-section should have.
5 kN
3m
9
0

m
m
1.5m
2 kN/m
B
A
C
50mm
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04.
(a) Design a suitable ordinary rigid flange coupling to connect
an electric motor to a reduction gear of a machine. The
motor has a rated output of 80 hp at 600 rpm. Working
stresses in materials to be used for different parts are
Flange (C.I): shear 1700 N/cm
2
, compression 8400 N/cm
2
Shaft (M.S): Shear 4750 N/cm
2
Bolt, Key (M.S): Shear 5800 N/cm
2
, compressions 9000
N/cm
2
.
These values take into account the service factor and
weakening effect of the keyway. Square keys are
recommended for fixing the flanges on the shafts. For your
calculations you may assume
Number of bolts = 4, Outside diameter of hub = 2d
P.C.D. of bolts = 3d
Width and depth of key = d/5 where d is the diameter of
the shaft. Make a fully dimensioned sketch of the coupling
(one view only) (20 M)
(b) Four masses m
1
= 100 kg, m
2
= 175 kg, m
3
= 200 kg and
m
4
= 25 kg are fixed to the crank of 20 cm radius and
revolve in planes 1,2,3 and 4. The angular positions of the
cranks in planes 2,3 and 4 with respect to the crank in
plane1 are 75
0
, 135
0
and 200
0
taken in the same sense. The
distances of planes 2,3 and 4 from plane 1 are 60 cm, 186
cm and 240 cm respectively. Determine the position and
the magnitude of the balance mass at a radius of 60 cm in
planes L and M located at the middle of planes 1 and 2 &
middle of planes 3 and 4 respectively. (10 M)
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(c) A 70 cm length of aluminum alloy bar is suspended from
the ceiling so as to provide a clearance A = 0.03 cm
between it and a 25 cm length of steel as shown in figure.
Determine the stress in the aluminum and in the steel due
to a 300 kN load applied 50cm from the ceiling. Given
, m 5 . 12 A
2
al
=
2
al
m / GN 70 E = , cm 25 A
2
s
=
2
s
m / GN 210 E = (10 M)
05.
(a) What is meant by the term non-conventional manufacturing
process? What are the areas of application of such
processes? (10 M)
(b) A plate cam, 25mm thick has bored hole at its center of
rotation in which a keyway, 5mm wide and 4mm deep, is
to be broached. Given that the empirical expression:
Broach tooth pitch ( mm ) = 1.77 SQRT( bore length),
determine , the length of the cutting portion of the broach
and the maximum force required to pull it through the hole
if the rise per tooth of the broach is 0.09mm and the force
to remove 1mm
2
of metal is 2500N. also explain why
knowledge of this force is desirable for manufacturing
process ? (10 M)
B
A
50 cm
20 cm
25 cm
3
0
0
k
N
A
l
u
m
i
n
u
m
S
t
e
e
l
C
D
E
0.03 cm
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(c) ABC company has to supply 30,000 switches per year to
its customer. This demand is fixed and known. The
customer uses its items in assembly operations and has no
storage place/space. A storage cost of Rs.10/unit is
incurred if the company fails to deliver the required units.
The set-up cost per run is Rs. 3,500.00. Determine:
(i) the optimum run size, q
(ii) the optimum level of inventory at the beginning of any
period
(iii)the optimum scheduling period
(iv) the minimum total expected annual cost.. (10 M)
(d) Explain different modes of tool failures with reasons?
Derive an expression for optimum cutting velocity for
minimum cost criteria machining process? (10 M)
06.
(a) Compare the similarities and differences present between
brazing and braze welding operations with respect to
(i) Mechanism of joint formation
(ii) Temperature of the joint
(iii) Heat sources
(iv) Filler rod materials used
(v) Applications.
(10 M)
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(b) What are the characteristics of a good gating systems?
Explain how the basic parts of gating system will satisfy
the characteristics? (10 M)
(c)The number of defects found for 20 items are as given
below:
Item no. 1 2 3 4 5
Defects 2 0 4 1 0
Item no. 6 7 8 9 10
Defects 8 0 1 2 0
Item no. 11 12 13 14 15
Defects 6 0 2 1 0
Item no. 16 17 18 19 20
Defects 3 2 1 0 2
Devise suitable control scheme for the future. (10 M)
(d) Compare the heat treatment process of hardening,
normalizing and annealing? Give one application for each
process. (10 M)
07.
(a) Explain different zones of wire drawing die with respect to
its uses and applications? (10 M)
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(b) The following information are given about a PERT
network:
Activity A B C D E F G H
Predecessor - - - A C B,D,E A C
(Time in
weeks)
1
3
5
2
3
4
3
4
5
2
9
10
4
5
6
5
6
13
2
4
6
0
3
6
Draw the network. Calculate critical path. What is the
probability of completing the project in 20 weeks or less?
(10 M)
(c) A pharmaceutical company has 100 kg of A, 180 kg of B
and 120 kg of C available per month. They can use these
materials to make three basic pharmaceutical products
namely 5-10-5, 5-5-10 and 20-5-10 where the numbers in
each case represent the percentage by weight of A, B and C
respectively in each of the products. The cost of raw
material is given below:
Ingredient Cost/kg (Rs.)
A 80
B 20
C 50
Inert ingredient 20
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Selling price of these products is Rs. 40.50, 43 and 45 per
kg respectively. There is a capacity restriction of the
company for the product 5-10-5 i.e. they can not produce
more than 30 kg per month. Formulate this problem as a
linear programming to maximize the companys total profit
for the month. (10 M)
(d) Write a program which will convert a temperature of C
degrees on the Celsius scale to the corresponding
Fahrenheit temperature and display the Fahrenheit
temperature. The two scale are related by the following
equation:
degF = (9/5)*degC + 32 program temp
(10 M)