CRB Mock

1) Newton’s 3 law of motion

Every object is in a state of rest unless an external force is applied upon it.
Every action has the same but opposite reaction.
Force is equal to the change in momentum per change in time. For a constant mass, F = ma
2) Newton’s law of cooling
The rate of heat loss of a body is directly proportional to the difference in the temperatures between the body
and its surroundings provided the temperature difference is small and nature of radiating surface remains same.
3) Boyle’s law
Pressure is inversely proportional to Volume at constant Temperature.
4) Temperature gradient.
Rate of change of temperature with displacement in a given direction.
5) Velocity Gradient
Rate of change of velocity between adjacent layers of fluid. (v/x)
6) Units of Heat
Joule (J), Rate of heat transfer is watt (W).
7) What is ?
Density!!!!
8) Newton’s law of motion
Every object is in a state of rest unless an external force is acted upon it.
9) What are Ferrous and Non-Ferrous materials?
Ferrous materials contain Fe.
10) What is the difference between an Alloy and Composite?
Alloy contains atleast one metal. Composite dosent contain any.
11) Full form CATIA?
Computer Aided Three Dimensional Interactive Application.
12) Thermal conductivity – Is the heat energy transferred per unit time and per unit surface area, by the
temperature difference. (W/m.K)

13) Heat flux – The amount of heat transferred per unit area per unit time from a surface. (W. )
14) Types of Heat exchangers – Shell and Tube, Plate, Regenerative and Adiabatic wheel. (explained further).
15) Least count of Vernier Calliper – 0.01 mm and micrometer – 0.001 mm
16) Go/ No Go gauge Taylor’s principle – The ‘Go’ gauge should always be designed that it will cover the MMC,
whereas a ‘Not Go’ gauge will cover LMC of a feature whether external or internal.
17) Impulse Turbine example – Pelton, Francis, Kaplan, Propellor. Difference between reaction and impulse is that
i) Draft tube is only used in Reaction.
ii) KE is used in Impulse. Reaction uses KE and PE.
iii) Reaction turbine has a pressure drop near the nozzle.
18) 1 foot = 12 inches
19) Cgs unit of work – erg (1 erg = J)
Cgs unit of force – Dyne (1 dyne = N)
20) Heat capacity – Ratio of heat addition by temperature difference. (J/K)
21) Specific heat – Amount of heat required per unit mass to raise the temperature of the body by 1 C. (J/kg.K)
 22) Module – Ratio of PCD to that of number of teeth’s.
23) Gear train – Arrangement of gears.
24) Difference between pair and joint – Pair refers to two machine members which are coupled together based on
relative motion, joint exists between two machine members joined together based on relative motion existing
between them.
25) Distortion energy theory – Gives a idea about how and under what load would a ductile material fail.
26) Emissivity – Total emissive power of a body to that of the emissive power of a black body.
27) Pressure range – Hydraulics (1500 to 2500 psi) and Pneumatics (80 to 100 psi).
28) Poison’s equation –
29) Fourier’s law – The time rate of heat transfer through a material is proportional to the negative gradient in the
temperature and to the area at right angles to that gradient through which the heat flows.

30) Thermal emissivity – Ratio of radiant emittance of heat of a specific object or surface to that of a standard black
body.
31) Pascal’s law – The intensity of pressure at any point in a fluid at rest is same in all directions.
32) Force - The agent that produces or tends to produce, destroys or tends to destroy any motion is called Force.
33) Assumptions for Bernoulli – Flow is incompressible and perfect, flow is continuous,

General

1) Which type of compressor is used in Gas Turbines?

3 types: Axial, Centrifugal and Mixed flow. Axial require less space and hence are famous for gas turbine power
plants since they need less space for medium to large thrust gas turbines.
2) Name some flow meters
Orifice meters, Venturi meters, Rotameters.
3) What is a nozzle?
Nozzle can control the direction of fluid along with changing some properties. Its main purpose is to increase
the velocity of the fluid. Used where high velocity and low pressure is required.
4) Relation of abs pressure, gauge pressure and atm pressure?
Abs pressure = Atm Pressure + Gauge pressure
5) For same compression ratio; which one has a greater eff petrol or diesel?
Petrol has higher eff because otto cycle rejects lesser heat for the same compression ratio than diesel cycle.
6) Archimedes principle
When a body is partially or totally immersed in a fluid, it experiences an upwards thrust equal to the weight of
the fluid displaced by it.
7) Newton’s law of gravitation
Objects attract each other with a force directly proportional to the product of the masses of the objects and
inversely proportional to the square of the distance between them.
8) Hooke’s law
Within elastic limit, stress induced ( ) in the solid due to some external force is always proportional with the
strain ( ).
9) Charles’ Law
At constant pressure, volume is directly proportional to Temperature.
10) Law of Conservation of Energy
Energy can neither be created nor destroyed. It changes from one form to another.
11) Kelvin-Planck statement – It is impossible for any system to operate in a thermodynamic cycle and deliver a net
amount of energy by work to its surrounding while receiving energy from a single reservoir.
12) Clausius – It is imp to construct a device which operates in a cycle and produces no effort other than the transfer of
heat from lower temp body to higher temp body.
13) What are Linkages?
Linkages are assembled bodies which take force and movement as inputs and outputs a different force/
movement.
14) What are Degree of Freedom in Linkages?
DoF is used to understand the configuration of a mechanical system or mechanism by determining its
independent parameters.
15) What are Gears? Different types of Gears?
Gears are devices used to transmit rotation, torque and power between shafts by engaging specially shaped
teeth on rotating disks. Different types of gears are – Spur Gears, Helical Gears, Bevel Gears.
16) What are the parameters needed to select a bearing?
Load, Size, Speed, Location, Starting torque, noise, lubrication supply and cost.
17) What are the different types of Springs? What are their applications?
Compression Springs: Switches, Automotive suspension
Tension Spring: Door Hinges
Torsion Spring: Mouse traps and Hair clips
Constant force spring: Clock mechanism
Belleville Spring/ Belleville Washer/ Spring Washer: Nut Bolt tightening operations.
18) What are Bearings? Different types of Bearings?
Bearings are devices made of an assembly of two surfaces that have relative motion.
Ball Bearings, Roller Bearings, Ball Thrust Bearing, Roller Thrust Bearing and Taper Roller Bearing.
19) What is Mechanical Engineering?
It is the branch of engineering which deals with the designing, constructing, maintaining and manufacturing of
various systems.
20) Difference between Engine and Machine?
Engine converts heat energy to Mechanical energy, but machine converts all forms of energy to mechanical
energy except heat energy.
21) What is viscosity? What is newton’s law of viscosity?
Viscosity is the property of fluid which measures the resistance of the fluid to the gradual deformation due to
shear stress.
Newton’s law: Shear stress on the fluid is proportional to the velocity gradient.
22) What are Newtonian and non-Newtonian fluids?
Newtonian follow the law: Water, air. Non: Blood, tar, paste.
23) What is the difference between a Pump and a Turbine ?
Pump transfers mechanical energy to fluid. Turbine transfers flow energy of the fluid to ME.
24) What are Turbo machines ?
Turbo machines are devices which transfer energy to or from the fluid by the dynamic action of rotating blades.
25) Reynolds number?
Is the ratio of inertia force to viscous force. less than 2300 then flow laminar. Between 2300 and
4000 flow transient and greater than 4000 then flow is turbulent.
26) What is Bernoulli’s equation? Why is it used?
Pressure head + velocity head + datum head = constant
27) Difference between heat engine and heat pump?
Heat engine produces work and transfers energy from high temp to low temp medium. In Heat pump external
work is needed to transfer energy from low to high medium.
28) What is a fluid ? Explain fluid mechanics ?
A fluid is a substance which always responses to shear stress and dosent have any definite shape. It may or may
not have any definite volume.
29) What are laminar and turbulent flows ?
When a fluid is flowing around an object or flowing through an object, the flow may be smooth or distorted.
Smooth flow occurs when the velocity is low and distorted when high. Low velocity is laminar and distorted
flow is turbulent.
30) What is buoyancy force ?
Upward force which is felt on an object simply immersed into a fluid.
31) What are compressible and incompressible flow ?
Compressible – variable density fluid flow.
Incompressible – fixed density fluid flow.
32) Different units of viscosity ?
In SI – Kg.m.s, in CGS – slug (ft.s). Value of viscosity is often very small so for that reason a more reasonable
unit is used which is called centipoise (cP).
33) Cycles used in Refrigeration.
Reversed Carnot Cycle.
34) Why reversed carnot is not possible ?
Because adiabatic processes are not possible to obtain due to losses in the pipes, condensers, compressors and
evaporator.
35) Which cycle is used in AC ?
Bell-Coleman cycle
36) In refrigeration system why heat rejected is more than heat absorbed ?
For cooling purpose it is necessary to reject more heat than the heat absorbed.
37) Difference between heat pump and refrigerator.
Heat pump gives heat by taking work input; refrigerators eject heat by taking heat input.
38) What is limiting friction ?
When an object is sliding over another, frictional force is developed in the contact surface. This friction force
creates a resistance. The maximum value of this frictional force is called the limiting friction.
39) What is Center of Gravity ?
Center of Gravity or CG is the point where the whole mass of a body acts.
40) How the pressure of the liquid is measured ?
By manometers.
41) What are manometers ?
These are pressure measuring devices for liquid. To measure the pressure in a point in the liquid manometers
balance the liquid column to another column or the same column of liquid.
42) How manometers are classified ?
Simple : - piezometer and U- tube
Differential
43) What are the uses of manometer ?
Simple Manometers are used to measure 1. high pressure of liquids 2. pressure in pipes and channels 3.
vacuum pressure.
Differential manometers are used for measuring pressure difference between two points in a pipe .
44) Name the different Thermodynamic Cycles
Otto Cycle, Diesel Cycle, Stirling Cycle, Joule or Brayton Cycle, Carnot Cycle, Ericsson Cycle etc
45) What is the difference between turbocharger and supercharger ?
Turbocharger uses a part of exhaust heat from the exhaust gases as a power source.
Supercharger uses a part of engine power to run. Turbo is not directly connected to engine. It decreases Carbon
emissions bcuz it has smog altering system.
Super is connected to the engine with a belt. It produces smog.
46) Why more lubricating oil is needed in two-stroke engines than four stroke engines ?
In two stroke engine the lubricant is mixed with the fuel. As a result some of the lub oil is blown out with the
process of scavenging and getting fresh charge. This phenomenon is not seen in four stroke engines.
47) What are the usual sequence of operation in IC engines ?
The sequence involve : Suction Stroke, Compression stroke, Combustion, Expansion or Working Stroke and the
exhaust.
48) What is the main difference between petrol engine and diesel engine ?
In petrol engine the ignition is initiated by the spark plug but in diesel engine the fuel and air mixture auto-
ignites after reaching a certain temperature.
49) What is the function of flywheel?
The main function of the flywheel is to store kinetic energy in the form of moment of inertia. It also reduces the
vibration in the engine and produces an even crank shaft rotational speed.
50) Static and Dynamic body
Static body is either in equilibrium or moving with constant velocity.
Dynamic body is body with accelerated motion.
Statics are time independent.
51) Rigid Body?
Combination of large number of mechanisms/ parts which are fixed together at set distances from each other.
52) Newton’s Law of Gravitation

53) Specific weight?

Weight per unit volume of a liquid at a standard temp and pressure. .
54) Specific gravity?
Ratio of specific weight of a liquid to the specific weight of pure water at standard temp (4 degree). It has no
units.
55) Specific volume?
Volume per unit mass of a liquid.
56) Coefficient of velocity, coefficient of discharge
Ratio of actual velocity of the jet to that of theoretical velocity at vena contracta.
Ratio of actual discharge to that of the theoretical discharge in a nozzle.
57) Venturi meter: It measures discharge of a liquid flowing through a part. It consists of 3 parts C cone, throat and D
cone. D cone length is 3 times the diameter of the cone; this gives streamline flow of fluid as well as frictional losses
are minimized.
58) U – tube manometer
Manometer are the devices in which columns of a suitable liquid are used to measure the difference in the
pressure between two points or between a certain point and the atmosphere.
59) Orifice – Orifice is the device used to measure discharge through a pipe. It works on Venturi meter principle.
60) Pitot Tube – It’s a small open tube bent at right angle. Used to measure velocity of the flow at required point in pipe.
It is determined by the rise of fluid in the pipe.
61) What is Enthalpy ?
Thermodynamic quantity, which equals to the total heat content of a system.
62) What is Entropy ?
The unuseful heat energy.
63) What is Stress ?
The internal resisting force per unit area of the component is called stress. When the fibers elongate tensile,
when contract compressive. . 1 MPa = 1 N/mm^2.
64) What is Strain ?
Deformation per unit length.
65) Assumptions made in Stress- Strain.
i) Material is homogenous.
ii) Load is gradually applied.
iii) Line of action of force passes through the geometric axis of cross section.
iv) Cross section is uniform.
v) There is no stress concentration.
66) What is shear stress?
When the external force acting on a component tends to slide the adjacent planes w.r.t each other, the resulting
stresses on these planes are called direct shear stresses. Average shear stress in a rivet .
67) Shear Strain?
The shear strain is the change in the right angle of a shear element. Within elastic limit, the stress-strain
relationship is given by; ; G = shear modulus of rigidity.
68) Relation between Modulus of rigidity and Poisson’s ratio.

69) Bulk modulus – K = Hydrostatic pressure/ Volumetric Strain

70) Poisson’s ratio – Is the ratio of strain in lateral direction to that in the axial direction.
71) Assumption’s for bending moment equation ?
i) Beam is straight with uniform cross section.
ii) Forces acting lie in a plane perpendicular to the axis of the beam.
iii) Material is homogenous, isotropic and obey Hooke’s law.
iv) Plane cross sections remain plane after bending.
72) What is torsional shear stress ?
The internal stresses, which are induced to resist the action of twist are called torsional shear stresses.
Mt = applied torque (N-mm)
R = radial distance of the fibre from the axis of rotation (mm)
J = polar moment of inertia of the cross-section about the axis of rotation (mm^4)
73) How are the dimensions of simple machine parts calculated ?
Dimensions are determined on the basis of pure tensile stress, pure compressive stress, direct shear stress,
bending stress or torsional shear stress.
74) What info is obtained from a tension test ?
Proportional limit, Elastic limit, Modulus of elasticity, Yield strength, Ultimate tensile strength, Modulus of
Resilience, Modulus of toughness, Percentage elongation, Percentage reduction in area.
75) Stress Strain Graph

76) Proportional Limit

The stress at which the stress-strain curve begins to deviate from the straight line.
77) Modulus of Elasticity
Ratio of Stress to Strain.
78) Elastic Limit
Defined as the maximum stress a material can withstand without permanent deformation.
79) Yield strength
The maximum stress at which a marked increase in elongation occurs without increase in the load.
For materials which do not exhibit a well defined yield point, the yield strength is defined as the stress
corresponding to a permanent set of 0.2% of gauge length. Proof strength is similar to yield strength.
80) UTS
UTS is the maximum stress that can be reached in the tension test. Stress at time of fracture is called breaking
strength. Breaking strength is slightly lower than UTS.
81) Mechanical Properties of Materials
Strength, Elasticity, Plasticity, Stiffness, Resilience, Toughness, Malleability, Ductility, Brittleness, Hardness
82) Strength – Ability of the material to resist, without rupture, external forces causing various types of stresses. Ex.
Tensile, Compressive, Yield, etc
83) Elasticity – Ability of the material to regain its original shape and size after the deformation, when the external
forces are removed.
84) Plasticity – Ability of the material to retain the deformation produced under the load on a permanent basis.
Elasticity Plasticity

Is the ability of a metal to regain its original Is the ability to retain the deformation
shape after temporary deformation under permanently even after the load is removed.
external force.
Elastic deformation is very less Plastic is relatively more

Atoms of metal are temporary displaced from Atoms of metal are permanently displaced from
their original positions but return back when the their original positions and take up new positions
load is removed
Stress strain is linear in elastic region Stress strain is non linear in plastic range

Elasticity is important in machine tool Plasticity is desirable for components made by

components press working operations.
85) Stiffness/ Rigidity – The ability of the material to resist deformation under the action of an external load. The
material that deforms the least within elastic limit is the stiffest. Modulus of elasticity is the measure of stiffness.
Stiffness is important while designing transmission shafting.
86) Resilience – Is the ability of the material to absorb energy when deformed elastically and to release this energy
when unloaded.
87) Modulus of Resilience – Is the strain energy per unit volume that is required to stress the specimen in a tension test
to the elastic limit point.
88) Toughness – Is the ability of the material to absorb energy before fracture takes place. It is the energy for failure by
fracture. Toughness decreases as temp increases.
89) Modulus of Toughness – Is the total area under stress-strain curve in a tension test, which represents the work done
to fracture the specimen. It is measured by Izod and Charpy impact testing machines.
90) Difference between Modulus of Toughness and Modulus of Resilience

91) Malleability – Defined as the ability of a material to deform to a greater extent before the sign of crack, when it is
subjected to compressive force. Malleability increases with temp.
92) Ductility – The ability of a material to deform to a greater extent before the sign of crack, when it is subjected to
tensile force. It is the permanent strain that accompanies fracture in a tension test. Ductility decreases as the temp
increases.
93) Brittleness – Property of a material which shows negligible plastic deformation before fracture takes place.
94) Hardness – Is defined as the resistance of the material to penetration or permanent deformation. It usually indicates
resistance to abrasion, scratching, cutting or shaping. 4 tests : Brinell, Rockwell, Vickers and Shore scleroscope. In
first 3 methods, an indenter is pressed onto the surface under a specific force. Shape is either ball, pyramid or cone.
The indenter are made up of diamond, carbide or hardened steel. Hardness depends upon the resistance to plastic
deformation. As hardness increases, strength also increases.
95) Cast iron – Is an alloy of iron and carbon, containing more than 2% of carbon. It also contains silicon, manganese,
Sulphur and phosphorus. Steels contain less than 1% carbon while cast iron normally contains 2 to 4 % carbon.
96) Benefits of Al Alloys –
a) Low Specific Gravity
b) Corrosion Resistance
c) Ease of Fabrication
d) High thermal Conductivity
97) Copper Alloys –
a) Brass – Copper and Zinc; Tensile strength is higher than copper, Cheaper, Excellent corrosion resistance,
better machinability, good thermal conductivity. Increase in Zinc, increase in strength and ductility.
b) Bronze – Copper and Aluminium;
98) Ceramics – A compound of metallic and non metallic elements with predominantly ionic interatomic bonding.
99) Plastics – Plastics are synthetic materials processed by heat and pressure. There are two types: Polymers and
Monomers. Thermoplastic: Is a polymeric material which softens when heated and hardens upon cooling.
Thermosetting: Is a polymeric material which once having cured or hardened by a chemical reaction does not soften
or melt upon subsequent heating.
100) Creep – It is a slow and progressive deformation of the material with time under a constant stress. Creep
deformation is higher at higher temp.
101) Creep Strength – Is defined as the maximum stress that the material can withstand for a specific length of time
without excessive deformation.
102) Creep rupture strength – Is defined as maximum stress that the material can withstand for a specified length of
time without rupture.

103) Static load – Is defined as a force, which is gradually applied to a mechanical component and which does not
change its magnitude or direction with respect to time.
104) Modes of failure :–
i) Failure by static deflection – In applications such as transmission shaft supporting gears, the maximum
force acting on the shaft, without affecting its performance, is limited by the permissible elastic
deflection. Lateral or torsional rigidity is considered as the criterion of design of such elements. The
modules of elasticity and rigidity are the imp properties and the dimensions are determined by load-
deflection equation.
ii) Failure by general yielding – Mechanical component made of ductile material loses its engineering
usefulness due to a large amount of plastic deformation after the yield point stress is reached.
Considerable portion of the component is subjected to plastic deformation, called general yielding.
There is a basic difference between general and localized yielding.
 Localized yielding – in the region of stress conc is restricted to a very small portion of the component
and is not considered significant. The yield strength of a material is an imp property when a component
is designed against failure due to general yielding.
iii) Failure by fracture – components made of brittle material cease to function because of the sudden
fracture without any plastic deformation. The failure in this case is sudden and total. In such cases UTS
of the material is an imp property to determine dimensions.
105) Cotter joint

106) Knuckle joint

107) What are levers ? Types of levers.

A lever is defined as a mechanical device in the form of a rigid bar pivoted about the fulcrum to multiply or
transfer the force.
Types :
i) First type : the fulcrum is located between the load and the effort arm. The effort arm can be kept less
than the load arm or equal to the load arm or more than the load arm. Example: Rocker arm for the
overhead valves of internal combustion engine, hand pump levers.
ii) Second type : Load is located between the fulcrum and the effort arm. Effort arm is always more than
the load arm and the mechanical advantage is higher than 1st. Example: In lever-loaded safety valves
mounted on boilers.
iii) Third type : The effort is located between the load and the fulcrum. The load arm is always greater than
the effort arm and the mechanical advantage is less than 1st. Example: A picking fork. Not
recommended in Eng applications.
108) What is mechanical advantage ?
Ratio of load to effort is called mechanical advantage. Ratio of effort arm to that of load arm is called leverage.
Mechanical Adv = Leverage
109) Assumptions for calculating stresses in a Cylindrical shell
i) Effect of curvature of the cylinder wall is neglected.
ii) Tensile stresses are uniformly distributed over the section of the walls.
 iii) Effect of the restraining action of the heads at the end of the pressure vessel is neglected..
110) Hoop Stress : The ratio of the product of the pressure and internal diameter of the cylindrical vessel to that of its
thickness.
111) Maximum principal stress is Hoop stress and Minimum principal stress is Longitudinal stress. The average of
them both is called maximum shear stress.
112) Permanent fastenings ?
Are those fastenings which can not be disassembled without destroying the connecting components. These are
either soldered, brazed, welded and riveted joints.
113) Temporary or detachable fastenings ?
Are those fastenings which can be disassembled without destroying the connecting components. These are
temporary screwed, keys, cotters, pins and splined joints.
114) Different types used applications :
i) Snap heads are usually employed for structural work and machine riveting.
ii) Counter sunk heads are used for ship building where flush surfaces are necessary.
iii) Conical heads are used for hand hammering.
iv) Pan heads have maximum strength, but difficult to shape.
115) Types of Riveted joints
i) Lap joint – One plate overlaps the other and the two plates are riveted.
ii) Butt joint – Main plates are kept in alignment butting each other and a cover plate is placed either on
one side or on both sides of the main plates.
a) Single strap butt – The edges of the main plates butt against each other and only one cover plate is
placed one side of the main plates and then riveted together.
b) Double strap butt – The edges of the main plates butt against each other and two cover plates are
placed on both sides of the main plates and then riveted together.
116) Imp terms used in riveted joints
i) Pitch – Distance from the centre of one rivet to the centre of the next measured parallel to the seam.
ii) Back pitch – Perpendicular distance between the centre lines of the successive rows.
iii) Diagonal pitch – Distance between the centres of the rivets in adjacent rows of zig-zag riveted joint.
iv) Margin or Marginal pitch – Distance between the centre of rivet hole to the nearest edge of the plate.
117) Failures of Riveted joint
i) Tearing of the plate at an edge
ii) Tearing of the plate across a row of rivets
iii) Shearing of the rivets
iv) Crushing of the plate or rivets
118) Advantages of welded joints over riveted joints
i) Welded structures are usually lighter than riveted structures.
ii) Welded joints provide maximum efficiency.
iii) Alterations and additions can be easily made in the existing structure.
iv) Welded structure is smooth in appearance.
v) In welded connections, the tension members are not weakened as in the case of riveted joints.
vi) Welded joint has greater strength. Often that of the parent metal.
vii) Welding provides rigid joints.
viii) Welding can be done in most of the places, but riveting requires clearance.
119) Disadvantages of Welded joints over riveted joints.
i) Due to uneven heating and cooling during fabrication, members may get distorted or additional
stresses may develop.
 ii) It requires a highly skilled labor and supervision.
iii) Since there is no provision for expansion and contraction in the frame, there is a possibility of cracks
developing in it.
iv) The inspection of welding work is more difficult than riveting work.

120) Types of Welding

i) Fusion – Thermit, Gas and Electric arc welding.
ii) Forge – Spot, seam, projection, upset and flash welding.
121) Weld Symbols
122) What are Keys ? Types of Keys.
Keys are machine elements used to prevent relative rotational movement between a shaft and the parts
mounted on it, such as pulleys, gears, wheels, couplings, etc. 3 types of keys :
i) Saddle keys – These are taper keys, with uniform width but tapering in thickness on the upper side.
a) Hollow saddle key – The key has a concave shaped bottom to suit the curved surface of the shaft,
on which it is used. The relative rotation between the shaft and the mounting is prevented due to
the friction between that shaft and key. Used for light duty only.
 b) Flat saddle key – Similar to hollow, except that the bottom surface of it is flat. Apart from the
tapered keyway in the hub of the mounting, a flat surface provided on the shaft is used to fit this
key in position. Used for light duty only. Flat is slightly superior than hollow.
ii) Sunk Keys – Standard form of keys used in practice and may be either square or rectangular in cross-
section. The end may be squared or rounded. Half the thickness fits into the shaft and the remaining
half in the hub. These keys are used for heavy duty.
a) Taper – These keys are square or rectangular in cross section, uniform in width but tapered in
thickness. Bottom surface is straight and the top is tapered. This key may be removed by driving it
out from the exposed small end. If this end is not accessible, the bigger end of the key is provided
with a head called gib.
b) Parallel or Feather keys – This key is uniform in width and thickness as well. These are used in
gears, clutches, etc. They permit relative axial movement. A clearance fit is required between the
key and the keyway in which it slides. Feather key is fitted using two or more screws on the shaft. 3
types of feather keys are : Peg, Single headed and Double headed.
iii) Splines – These keys are made integral with the shaft, by cutting equi spaced grooves of uniform cross-
section. The shaft with splines is called splined shaft.
iv) Woodruff key – It is a sunk, in the form of a circular disc of uniform thickness. As the bottom surface of
the key of circular, the keyway in the shaft is in the form of a circular recess to the same curvature as
the key. Woodruff is usually used on tapered shafts of machine tools and automobiles.
123) Cotter joints
A cotter is a flat wedge shaped piece, made of steel. Uniform in thickness but tapering in width, generally on
one side. Cotter are used to connect two rods, subjected to tensile or compressive forces along their axes.
These aren’t suitable under rotation.
124) Shaft Couplings – Are used to join or connect two shafts in such a way that when both the shafts rotate, they act
as one unit and transmit power from one shaft to the other. Types – Rigid coupling, Flexible coupling, Loose or dis-
engaging coupling and Non-aligned coupling.
125) Rigid coupling – Are used for connecting shafts having collinear axes. Types – Sleeve/ Muff coupling and flanged
coupling.
126) Sleeve or Muff coupling – Simplest of all coupling. Consists of a sleeve called muff, generally made of cast iron,
which is fitted over the ends of the shafts. After properly aligning the keyways in the shafts and sleeve, a sunk key is
driven-in; making the coupling. Types – Butt-muff, Half-lap muff, Split-muff
127) Flanged couplings – Standard forms of couplings, most extensively used. Flanges are either fitted or provided at
the end of the shafts. Flanges are fastened together by means of a number of bolts and nuts. The no and size of
bolts depend upon the power to be transmitted and hence shaft diameter. Types – Coupling with detachable
flanges, solid flanged coupling.
128) Flexible coupling – Flexible couplings permit relative rotation or variation in the alignment of shaft axes within
certain limits. Types – Bushed pin type flanged coupling and Compression coupling
129) 120 (Narayana)
130) Kinematic viscosity – Ratio of dynamic viscosity and density of a fluid.
131) Types of Fluid –
i) Ideal fluid
ii) Real fluid
iii) Newtonian fluid
iv) Non Newtonian fluid
v) Ideal plastic fluid
132) Relationship between Bulk Modulus (K) and pressure (p) for a Gas
i) Isothermal Process – K = p
ii) Adiabatic process – K=pk, k is ratio of specific heats
133) Surface Tension – Is defined as the tensile force acting on a surface of a liquid in contact with a gas or on the
surface between two immiscible liquids such that the contact surface behaves like a membrane under tension.
Denoted by N/m.
134) Capillarity – Defined as the phenomenon of rise or fall of a liquid surface in a small tube relative to the adjacent
general level of liquid when the tube is held vertically in the liquid. The rise of liquid surface is known as capillary rise
while the fall of the liquid surface is known as capillary depression. Value depends upon specific weight of the liquid,
diameter of the tube and surface tension of the liquid.
135) Pascal’s law – Pressure or intensity of pressure at a point in a static fluid is equal in all directions.
136) Hydrostatic law – Pressure at any point in a fluid at rest is obtained by Hydrostatic law that says that the rate of
increase of pressure in a vertically downward direction must be equal to the specific weight of fluid at that point.
137) Abs pressure – Defined as the pressure which is measured with reference to abs vacuum pressure.
138) Gauge pressure – Pressure which is measured with the help of a pressure measuring instrument in which atm
pressure is taken as datum.
139) Vaccum pressure – Defined as the pressure below the atm pressure.
140) Manometer – Devices used for measuring pressure at a point in a fluid by balancing the column of fluid by the
same or another column of the fluid. Types – Simple and Differential.
141) Simple Manometer – Peizometer, U-tube manometer, Single column
142) Peizometer – Simplest form of manometer. One end is connected to the point where pressure is to be measured
and another end is open to the atmosphere. Rise of liquid gives pressure head at that point.
143) U – Tube manometer – Consists of a glass tube bent in U-shape, one end of which is connected to a point at
which pressure is to be measured and other end remains open to the atmosphere. Tube generally contains mercury
or any liquid whose specific gravity is greater than the specific gravity of the liquid whose pressure is to be
measured. .
144) Temperature Lapse Rate (L) – Defined as the rate at which the temperature changes with elevation. If
k = 1, temperature is 0 if k 1, temp decreases with increase of height.
145) Joule’s law in thermo
Change in the internal energy of a perfect gas is directly proportional to the change of temperature.
146) Polar moment of inertia – Resistance to torsional movement.
147) Moment of inertia – Resistance to angular movement
148) Projection – Is defined as a representation of an object on a two dimensional plane.
149) Orthographic projection – When the point of sight is imagined to be located at infinity so that the rays of sight
are parallel to each other and intersect the plane of projection at right angle to it.
150) Sectional View – Obtained by imagining the object, as if cut by a cutting plane and the portion between the
observer and the section plane being removed.
151) Half section view – Is preferred for symmetrical objects, cutting plane removes only one quarter of an object.
152) Auxiliary sections – A sectional view projected on an auxiliary plane, inclined to the principle planes of
projection, shows the cross sectional shapes of features such as arms, ribs and so on.
153) Oblique projection – z and y axis make 90 angle, others make 135 angle.
154) Isometric – All the planes make 120 degree angle to observer.
155) Hydraulic and Pneumatic pressure range – 1200 to 2500 psi (hy), 50 to 100 psi (pneu).
156) Meta center – point about which a floating body starts oscillating, when given a small angular displacement.
157) Meta centric height – Distance between the CG of the floating body and the metacenter.
Manufacturing Processes

1) Manufacturing processes
i) Primary shaping processes - The processes used for the preliminary shaping of the machine component are
known as primary shaping processes. The common operations used for this process are casting, forging,
extruding, rolling, drawing, bending, shearing, spinning, powder metal forming, squeezing, etc.
ii) Machining processes - The processes used for giving final shape to the machine component, according to
planned dimensions are known as machining processes. The common operations used for this process are
turning, planning, shaping, drilling, boring, reaming, sawing, broaching, milling, grinding, hobbing, etc.
iii) Surface finishing processes - The processes used to provide a good surface finish for the machine
component are known as surface finishing processes. The common operations used for this process are
polishing, buffing, honing, lapping, abrasive belt grinding, barrel tumbling, electroplating, superfinishing,
sheradizing, etc.
iv) Joining processes - The processes used for joining machine components are known as joining processes. The
common operations used for this process are welding, riveting, soldering, brazing, screw fastening, pressing,
sintering, etc.
v) Processes effecting change in properties - These processes are used to impart certain specific properties to
the machine components so as to make them suitable for particular operations or uses. Such processes are
heat treatment, hot-working, cold-working and shot peening.
2) Casting
i) Sand mould casting : The casting produced by pouring molten metal in sand mould is called sand mould
casting. It is particularly used for parts of larger sizes.
ii) Permanent mould casting : The casting produced by pouring molten metal in a metallic mould is called
permanent mould casting. It is used for casting aluminium pistons, electric iron parts, cooking utensils,
gears, etc.
iii) Slush casting : It is a special application of permanent metal mould casting. This method is used for
production of hollow castings without the use of cores.
iv) Die casting : The casting produced by forcing molten metal under pressure into a permanent metal
mould (known as die) is called die casting. The die casting method is mostly used for castings of non-
ferrous metals of comparatively low fusion temperature. This process is cheaper and quicker than
permanent or sand mould casting. Most of the automobile parts like fuel pump, carburetor bodies,
horn, heaters, etc are made by this process.
v) Centrifugal casting : The casting produced by a process in which molten metal is poured and allowed to
solidify while the mould is kept revolving, is known as centrifugal casting. The examples of centrifugal
castings are pipes, cylinder liners and sleeves, rolls, bushes, bearings, gears, flywheels, gun barrels,
piston rings, brake drums, etc.
3) Forging
It is the process of heating a metal to a desired temperature in order to acquire sufficient plasticity,
followed by operations like hammering, bending and pressing, etc. to give it a desired shape. The
various forging processes are :
1. Smith forging or hand forging
2. Power forging,
3. Machine forging or upset forging, and
4. Drop forging or stamping
4) Range of Surface Roughness :

5) Casting processes – In such processes, molten metals such as cast iron, copper, aluminium or non metals like
plastic are poured into the mould and solidified into the desired shape, e.g., housing of gear box, flywheel with
rim and spokes. Types :- Sand, Steel-mould, permanent mould, die-casting, centrifugal or investment casting.
6) Deformation processes – In such processes, a metal either hot or cold is plastically deformed into the desired
shape. Forging, rolling, extrusion, press working are the examples. Example is connecting rods, crankshafts, I-
section beams. Type :- Forging; the metal in the plastic stage, rather than in the molten stage, is forced to flow
into the desired shape. Hand forging, drop, press or upset.
7) Material Removal or Cutting processes – In such processes, the material is removed by means of sharp cutting
tools. Turning, milling, drilling, shaping, planning, grinding, shaving and lapping are classic examples. The
products include transmission shafts, keys, bolts and nuts.
8) Material joining processes – Bolting, welding and riveting are essential for the assembly of the product.
9) Hot working – Metal deformation processes that are carried out above the recrystallisation temperature are
called hot working. Hot rolling, forging, spinning, extrusion and hot drawing.
a) Advantages :-
i) Hot working reduces strain hardening.
ii) Components have higher toughness and ductility. Better resistance to shocks and vibrations.
iii) Increases the strength of metal by refining the grain structure and aligning the grain of the metal with
final counters of the part.
iv) It reduces residual stresses in the component.
b) Disadvantages :-
c) Results in rapid oxidation of the surface due to high temp
d) Components have poor surface finish. It is expensive.
10) Cold working – Metal deformation that are carried out below the recrystallisation temp are called cold working.
Cold rolling, forging, spinning, extrusion and cold drawing are some examples.
a) Advantages :-
i) Component have higher hardness and strength.
j) Components have better surface finish. Dimensions are very accurate.
k) Tooling is cheap.
b) Disadvantages :-
i) Reduces toughness and ductility. Components have poor resistance to shocks and vibration.
j) It induces residual stresses in the component.
k) Proper heat treatment is required to relieve stresses.
11) Machining Process is divided into :
i) Cutting : Turning, Boring, Drilling, Milling, Shaping, Planing, Broaching, Gear cutting.
ii) Abrasion : Grinding, Honing, Superfinishing, Polishing, Buffing, Lapping, Abrasive flow.
12) Machining by cutting is further divided into :
i) Single point – Turning, Boring, Shaping, Planing.
 ii) Multi point – Drilling, Reaming, Milling, Broaching, Hobbing, Sawing, Filling.
13) Classification of Tool Materials :
i) Ferrous – Carbon tool steel, Alloy tool steel, High speed steel (Molybdenum, Tungsten)
ii) Non ferrous – Cast alloys (Blackalloy, Crobalt, Haynes), Cemented carbides, Ceramics, Diamond.
14) Discontinuous chips – Brittle materials such as cast iron, bronze and some ductile materials are cut. Brittle
materials do not have the tendency to undergo high shear strains developed in the cutting operation.
Other machining conditions that lead to the formation of this type of chip include :
i) Materials that contain hard impurities and inclusions.
ii) Very low/ Very high cutting speeds.
iii) Large depth of cuts
iv) Very low rake angles
v) Low stiffness of the machine tool
vi) Lack of effective cutting fluid
15) Continuous chips – Formed at high cutting speeds and large rake angles. Ductile material such as mild steel,
copper and aluminium. Other factors that lead to continuous chip formation are:
i) High cutting speeds.
ii) Small depth of cut.
iii) Sharp cutting edge.
iv) Large rake angles.

Drawing
1) GD&T Symbols :
i) Flatness
ii) Straightness
iii) Circularity
iv) Cylindricity
v) Profile of a Line
vi) Profile of a Surface
vii) Perpendicularity
viii) Angularity
ix) Parallelism
x) Circular Runout
xi) Total Runout
xii) Position
xiii) Concentricity
xiv) Symmetry
xv) Maximum Material Condition
xvi) Regardless of Feature Size
xvii) Least Material Condition
xviii) Datum feature symbol
Units

1 inch = 25.4 mm = 0.0254 m

1 joule = 0.239 gram cal = 0.00027 watt hour = 0.00094 british thermal unit

1 Pa = Bar =

1 atm = 101325 Pa

1 m/s = 3.6 km/hr

0 Celsius = 32 Fahrenheit = 273.15 Kelvin

1 Lt = 0.001 =

Statements

1) Parallelogram law of forces – Two forces acting simultaneously on a particle, be represented in magnitude and
direction by two adjacent sides of a parallelogram, then their resultant be represented in magnitude and
direction by a diagonal of a parallelogram which passes through their points of intersection.
2) Triangle law of forces – If two forces acting simultaneously on a particle be represented in magnitude and
direction by the two sides of triangle taken in order, then their resultant is represented in magnitude and
direction by the third side of the triangle taken in opposite order.
3) Polygon law of forces – If number of forces acting simultaneously on a particle, be represented in magnitude and
direction by sides of a polygon taken in order, then their resultant is represented in magnitude and direction by
the closing side of the polygon taken in opp order.
4) Lami’s theorem – If three coplanar forces acting at a point be in equilibrium, then each force is proportional to
the sine of the angle between the other two forces.
5) Limiting angle – angle which the resultant reaction (R) makes with the normal reaction.
6) Angle of repose – Angle of inclination of the plane to the horizontal, at which the body just begins to move down
the plane.
7) Velocity ratio – Ratio of distance moved by the effort to the distance moved by the load.
8) Self locking (Non – reversible) - If the machine is not able to do some work in the reversed direction after the
effort is removed, then the machine is known as self locking. It requires that the efficiency of that machine be
less than 50%.
9) Speed – Distance covered per time.
10) Velocity – Distance per unit time.
11) Acceleration – Rate of change of velocity of a body.
12) Angular displacement – Angle described by a particle from one point to another, with respect to time.
13) Angular velocity – Rate of change of displacement of a body.
14) Angular acceleration – Rate of change of angular velocity.
15) Work – When force acts on a body and body undergoes displacement in the given direction, then the work is
said to be done.
16) Power – Rate of doing work per unit time.
17) Energy – Capacity to do work.
18) Strain energy - Potential energy stored by an elastic body when compressed or deformed.
19) Bearing stress/ Crushing stress – Localized compressive stress at the surface of contact between two members
that are relatively at rest is known as bearing stress or crushing stress.
20) Types of beams – Cantilever beam, Simply supported beam, Overhanging beam, Fixed beam, Continuous beam.
21) Stiffness of a spring – Load required to produce a unit deflection in a spring is called stiffness of a spring.
22) Discharge – Quantity of liquid flowing per second through a section of pipe.
23) Momentum equation in fluids – Net force acting on a mass of fluid is equal to the change in momentum of flow
per unit time in that direction.
24) Impulse momentum equation – Impulse of a force (F) acting on a fluid mass in a short interval of time is equal to
the change of momentum in the direction of force.
25) Coefficient of contraction – Ratio of area of jet at vena contracta to the area of orifice.
26) Vena contracta – Point at which streamlines first become parallel.
27) Coefficient of resistance – Ratio of loss of head in the orifice to the head of water available at the exit of the
orifice.
28) Hydraulic gradient line – Line representing the sum of pressure head and potential head with respect to some
reference line.
29) Total energy line – Line representing sum of pressure head, datum head and velocity head with respect to some
reference line.
30) Zeroth law – When two bodies are in thermal equilibrium with third body, they are also in thermal equilibrium
with each other.
31) First law – Energy can neither be created nor destroyed.
32) Second law – Clasius = Impossible for self acting machine working in a cyclic process, to transfer haet from a
body at lower temp to a body at higher temp without aid of external agency. Kelvin – Planck = Impossible to
construct an engine working on a cyclic process, whose sole purpose is to convert heat energy to work.
33) Sliding pair – When two elements of a pair are connected in such a way that one can only slide relative to the
other.
34) Turning pair – When two elements of a pair are connected in such a way that one can only turn or revolve about
a fixed axis of another link, the pair is known as turning pair.
35) Rolling pair – When two elements of a pair are connected in such a way that one rolls over another fixed link,
the pair is known as rolling pair.
36) Screw pair – When two elements of a pair are connected in such a way that one element can turn about the
other by screw threads.
37) Spherical pair- when two elements of pair are connected in such a way that one element turns or swivels about
the other fixed element.
38) Lower pair – when two elements of a pair have surface contact when relative motion takes place.
39) Higher pair – when two elements of a pair have a line or point contact when relative motion takes place.
40) Centrifugal pumps – Is a machine which converts KE of water into PE before the water leaves its casing.
41) Indicated mean effective pressure – Is obtained from the indicator diagram drawn with the help of an engine
indicator.
42) Indicated power – Is the power actually developed by the engine cylinder.
43) Brake power – Power available at the crankshaft. BP is less than IP.
44) Instantaneous center – Of a moving body is defined as the center which goes on changing from one instant to
another. The locus of all such center’s is called centrode.
45) Spur gear – When two parallel and co-planar shafts are connected by gears having teeth parallel to the axis of
the shaft, then these gears are called spur gear.
46) Bevel gears – When two non-parallel or intersecting, but coplanar shafts are connected by gears, then these
gears are called bevel gears.
47) Worm gears – When two non-intersecting and non-parallel shafts are connected by gears, these gears are called
skew bevel or worm gears.
48) Module – Ratio of PCD to number of teeth’s.
49) Circular pitch – Distance measured on the circumference of the pitch circle from a point on one tooth to the
corresponding point on the next tooth.
50) Nominal size – Size of a part specified in the drawing as a matter of convenience.
51) Basic size – Size of a part to which all limits of variation are applied to arrive at final dimensioning of mating
parts.
52) Actual size – Actual measured dimension of the part.
53) Allowance – Difference between the basic dimensions of the mating parts.
54) Tolerance – Difference between the upper limit and lower limit of a dimension.
55) Zero line – Straight line corresponding to the basic size.
56) Fundamental deviation – One of the two deviations which is conventionally chosen to define the position of the
tolerance zone in relation to zero line.
57) Fit – The degree of tightness and looseness between two mating parts.