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S
ECT
ION
A
1 A
nsw
er
l l o
f the
follo
wing
:
a) T
he
too
thpro
files
o f
bo
th th
e
g
ears
u
sed
ina
ge
ar driv
e are
-inv
olut
e
wit
h
20
p
ress
ure an
gle
12
m
m
m
odu
le and
1
0m
m
add
endu
m. The
p in
ion
and
t
he
g
ear hav
e
36 and
96
te
eth r
espe
ctive
ly .
Find
the
len
gtho
f
p
ath
of
c
ontac
t, a
rc
of
c
onta
ct a
nd
the
c
onta
ct ra
tio.
Show
the p
ath
of co
ntact
w
ith a s
ketc
h.
8
b) T
he f
ollow
ing d
ata
ref
e r t
o a s
ingle
-cyl
inde
r re
cipro
cati
ng eng
ine
Spee
d 25
0 r .
p .m .
St
roke
=
300 m
m
Mas
s
of re
cipro
cati
ng
pa
rts
50k
g
M
ass o
frev
olvin
g p
art s
at
150
m
m
ra d
ius
38
kg
I
f two
-thir
ds
of r
ecipr
ocat
ing
p
ar ts and
ll
t
he re
volv
ing
par
tsar
eto
be
bal
ance
d,
f
ind
-
i}
t
heb
alan
cema
ss
req
uire
d at
a
ra
dius
of41
0mm
;
ii}
the
res i
dual
un
bala
nce
fo
rce w
hen
the
cran
k ha
s
ro tat
ed 60
fro
m
in
ner
dead
cen
tre.
c) A
cy l
indri
ca l sh
aft,
8
0 mm
i
n
d
iam
eter,
is
subj
ecte
dto
a m
axim
um
ben
ding
mo
men
t
of
2 5
k N -
m
and
a
tw is
ting
m
om
ent of 4
2 kN
-m .
F
indt
hema
ximu
m
p
rinc
ipal
str
ess d
evel
oped
i
n th e
shaf
t. If th
eyie
ld
st res
s of
th e
sha
ft ma
teria
l
i
s
38
0
M
Pa
d
eterm
ine
the fa
ctor
o f s a
fe ty
of
the
sha
ft
ac
cord
ing
to t
he m
axi
mum
8
sh
earin
g s
tress
t
heor
y of fa
ilure
.
8
d)
A ho
rizo
ntal
s im
ply
su
ppo
rted
b
eam
AB ,
8 m
long
c
ar ri
es a tot
al
unifo
rm l
y
distributed
load
of
300
kN. The
beam
is
supported
atA
an
d a
t a
po
int C
be
twee
n
A
an
dB
whe
re ov
erha
ng
C
is
x. Det
ermi
ne
the
v
alue
of
x if
th
e
mid
poin
t of
th e
be
am
B is t
o be
a
poin
t of in
llexi
on.
8
e)
D if
fere
n tiat
e t
he ch
arac t
eri s
tics o
fba
sic c
ubic
an
d o
rtho
gona
l
crys
tal
syste
ms.
Giv
e
at l
eas t th r
ee ex
amp
les
of
ea
ch cate
go ry
of
crys
tal sy
stem
.
8
2
a) I
n a
quic
k-re
turn
moti
on
of t
he cr
ank
a
nd
sl
otted
le v
er ty
pe t
he
rati
o of
m
axim
um
velo
citie
s
du
ringre
turn an
d
forw
ard
mo
tion
s is 2 .
I f
th e
len
gth
of
s
trok
eis
250
m
m, fin
d-
i}
the
length
of
th e
slotted lever;
ii}
t
he
ratio
o
fti
mes
ofcu
tt in
g
a
nd
retu
rn
stro
kes
;
iii)
th
e max
imum
cu
tting
vel
ocity
per
sec
ond
i he
cra
nkro
tates
a
t
30
r.p.m
. 10
b)
A
pu nc
hin
g mach
ine
car
ries
out
5 ho
les
per
m
inute
. E
achho
le o
f 32
mm
dia
met
er
in 35
m
m th ic
k pla
tereq
uire
s 10
N-m
of
ene
rgyj
mm
2
of the
she
ared
area.
The
pu
nch h
as
a s
trok
e of
90mm
F
ind
th e p
ower
of
th e
moto
r
re
quir
ed
if
the
m
eansp
eed
of
th eflyw
hee
l is 2
5
mjs.
I
fthe
t
otal
fluct
uatio
n
of spe
ed
i s no
t
to e
x cee
d 3
of
th
e m
eansp
eed
d
eterm
ine
th e
mas
s of
the
fl
ywh
eel.
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8/11/2019 IFS Mechanical Engineering 2013 Part 1
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SECTI
ON B
5 Answ
er l l
of th
e foll
ow ing
:
a) E
xplain
the
ne
ed for use
of
unconv
ention
al machi
ning
proce
sses compa
red
t
o the conv
entiona
l one
s.
Nam
e
a
ny fi
ve uncon
ventio
nal pro
cesses
with
one
e
xample
of
its appli
cation.
Explai
n the
basic
princip
le of wa
teijet m
achin
ing.
8
b
) In
ameta
lcutting
experim
en t,
the
tool
lifewas
fou
nd to
vary wi
th th
e cuttin
g
s
peed
in the
follow
in g
mann
er
Cu
tting spe
ed V
Tool
life T
(in m/m
in)
(
in m in )
10
0
12
0
130 50
D er
iv eTa
ylors t
oo l life
equa
tionfor th is
op
eration
and es ti
mate
the
to o l life
at
a spe
ed of 25 m
/ s
ec. Als
o
e
stimat
ethe cu t
ting
speed
for a
tool lif
e
o
f 80 mi
n.
8
c) Expla
in, wi
ththe
help of
sketch
es, the
conce
pts of h
ole ba
sis an
d
s
haft
bas
is in
t
erms
of assem
bly
fit
specifi
cations
.
Wh
ich of
the
tw ois prefer r
ed an
d, wh
y?
8
d)
A nalu
miniu
m rod,
6 25 romdi
amete r
, is d
rawn
into
a wi
re 5 60 romd
iamete
r.
N
eglect i
ng fric
t ionbet
ween the
rod
and the
dies,
determ
ine th
e
dr
awing
str
ess
and
the
reductionin
area
when the
y ield
st ress
fo r
alumin ium
is
35
N
mm
2
Al
so calcul
ate th
etange
ntial
stres
s at the
exit .
8
e
) Wh
at is work
s
ampli
ng? A
p ilo t
study sho
ws 30
in e
ffe ctiv
e
time
i
n ajob o
rder
shopwh
ich
has 10
gene
ral p
urpos
e ma
chines
. A work
sam
pling
study
is
plann
ed . Com
pute
the num
ber
of
ob
servati
ons
that
are
r
equire
d
to
e
nsure a
n
ac
curacy
of
5 with
95
conf
idence
level.
6
a) The
tabl
ebe
low lists
1
2
w
ork
elem
ents alon
g w
ith the
ir nu
mber
of
predecessors
and
time
duration
inminutes.
Design a
suitableproduction
l ine
con
si sting
o
f app
ropriat
enu
mber of
wor
kstatio
ns as
sumin
g cyc
le time o
f
1 0 min.
A
lso
c
omput
e the
l ine
efficie
ncy , bala
nce d
elay an
d
s
mooth
ness
in
dex:
ork ele
m ent
2
3 4
5
6
7
8
9
1
0
1
2
No o
f pred
e essors
0
2
2
5
6
7
6
6
7
im e
o
fcom
pletion
in
min)
5 3
4
3 6
5
2
6
4 4
7
8
W ri
te the
steps u
sed in
soluti
on .
1
5
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{b)
c)
A com
pan
y
man
ufac
tures
tw
o prod
uct s
A
and
B
Th
e m
anu
fac t
uring
an
d
be
low
:
a
rketi
ng
da
ta for
the
t
w o p
rodu
cts a
re
g ive
n
epar
tment
Pr
oduct
A
P
rodu
ct B
Ca
pacit
y
W
elding
2 0
m an
-h ou
rs
2
5 ma
n
hou
rs
1000
m an
-h ou
rs
achin
es
3 0 ma
n-hou
rs
1 5 ma
n
ho
urs
1
200
m an
-hour
s
A
ssem
bly
5
man
hour
s
4
0m
an
ho
urs
120
0 m a
n-ho
urs
P
rofit
I
f 120
/un i
t
If 10
0/
uni
t
Find
the
pr
od uc
t-mi
x
to
max
imiz
e p ro
fi t
assu
mmg
th
at
w
hat
ever
is
pro
duc
ed
w
ill
be
sold
A
fun
ction
F
x) is
defm
ed
as
f
ollo w
s :
Fx
) =
3
-
bx
2
c
x-d
if
X>
1
=
0
if
x=
=
3
bx
-ex
d
if
X
1
W rit
e a
FOR
TRAN
p
ro gr
am
that rea
ds
th
e valu
es o
f a
b,
c
, d
x
and
f ind
the
valu
es of
F x)
in
pr i
nt.
7. a)
A
co
mpan
y
is
enga
ged in
th e
a
ssem
bl y
of a w
ago
non
a co
nvey
or.
500
wa
gons
are
requ
ired
per
d
ay . Prod
uc ti
on
ti
me a
va il
able
per d
ay i
s 420 m
inu
tes.
Th
e
. othe
r in f
orma
tion
is
g ive
n in
th
e table
be
low r
egar
ding
as
sem
bly st
eps
and
prece
den
ce r
elati
onsh
ips.
Fin
d the
mi
nim
um n
umb
er ofw
ork
stati
on s
bal
ance
IS
10
dela
y
and l
in e e
ffic ie
ncy
:
15
Activ
ity t
hat m
ust
A
ctivit
y
Time
in
sec
)
pre
ede
A
45
-
A
c
09
B
D
50
E
15
D
F
12
c
G
12
c
H
12
E
I
1
2
E
J
08
F
G
H I
K
09
-
Tot
al
195
5
[P.T
.O.
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b
)
Classi
fy the cost
s ass
ociated
w
ith
the
mana
gemen
t
of
qu
ality.
A
co
mpany
B
alance
Sheet shows
the
fo l
lo w ing ex
pendit
ure
on
qu
ality
c
ontrol.
Group
the
m in app
ropriat
e quali t
y c
ost :
1
0
SL No
Ite
m
xp
enditure
in
lakhs
of
f)
1
Vend
or quali
ty ssur
nce
2
0
2 Produc
ts r
eturned
fr om
field
1
5
3
Warran
ty
claims
04
4
Sc
rap
30
5
Fi
eld test
ing befo
re com
m iss ion
in g
10
6 R ew ork 20
7
Rec
eiving in
spectio
n
10
8
ow nti
m e
10
9 M
aterials
consum
ed dur
ing m ea
sureme
nts
04
10 Qu
alitytrainin
g
1
0
eprec
iation o
equip
ment
25
To tal : 58
c)
man
ufactu
ring com
pany
requ
ires specia
l ge
ars
a
t
the ra
te of 3
00 num
bers
per y
ear.
Each
gear
3
80. The
p
rocure
men t
c
ost
and inve
ntory
car
ry ing
cost
a
re
es ti
mated
to b
e 30
0
and 20%
resp
ec t ive
ly. If th
e
s
upplie
r
offers
a dis
count
2
0 per
g
ear
on
a
norder
o
f 200
gears
o
r more,
w
ill i t be adv
isable
to
ava
il the di sc
ount?
Wh
at s
hou ld
be th
e orde
r quan
tity?
15
8. a}
i)
Wha
t
is t
he
d iffe re
nce
be
tween
a
ji
gand
a fi
xture?
Expla
in with
the he
lp o
f
one examp
le
fo r
e
ach.
4
ii)
E
xplain
th e 3
: 2 : 1
prin
ciple of
locati
on.
b
) i)
D
ifferen
tiate among
the
sim
ple comp
ound
and pr
ogress
ive
dies
ii)
sym
metri
ca lc
up
o
f cir
cular c
ross sectio
n wit
h di
ameter
40 mm a
nd
height
60 m
m
wi
th
a com
erradius
of
2 mm
is to
be o
btaine
d in
C20 s
teel
ofO
m
m
th
icknes
s. Calcu
late th
e b
lank s
izefor th
edrawncu
p.
Will
i t
be
po
ssible
to
dr a
w t
he cup
in s
ing le step?
6
8
6
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c) Two holes are to be drilled with a 10 mm diameter drill on a job
as
shown
below:
~ h o l e s ~
i .
o o L - - - - - - - - - - - - - - - ~
: 5
60
90
l
40
_ro
The
drill rotates
at
500
r.p.m.
and feed rate is 200 mmfmin. How do you code
the
information n
i) ftxed block format;
ii)
T B sequential format;
iii) word
address
format?
2
7
BS4 200
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