Mechanical Interview

Questions

TANUJA P T
Copyright © 2020 TANUJA P T

All rights reserved.

ISBN:
 DEDICATION

To all my students and readers of this book, may you succeed in life!
1. Draw a sketch of a Gib key and a Woodruff key.

Ans.

2. Maruti 800 cc Four Stroke engine. Is this statement right?

Ans.
True, Maruti 800 cc is a Four Stroke engine.

3. What is the maximum acceleration if the coefficient of friction

is 0.2? Explain.

Ans.

Maximum acceleration is given by: m amax −μmg=0 -(1)

where, μ=¿ coefficient of friction = 0.2

Substituting the value of μ in (1) we get maximum acceleration is

m
a max=0.2× 9.81=1.962 2
s

4. What are the different strokes in a cycle of the diesel engine?

What is the compression ratio of a diesel engine?

1
 Ans.
The four stokes are suction, compression, power and exhaust.
Compression ration ranges between 15:1 to 23:1.

5. Is a blower, compressor and a fan the same?

Ans.
Fan- moves large amount of gas with low increase in pressure,
Blower- moves air with moderate increase in pressure,
Compressor- compresses gas to a very high pressure.

6. The conversion equation of Celsius to Kelvin.

Ans.
Kelvin scale= Celsius +273

7. Why is heat generated in a compressor?

Ans.

Because of compression of fluid inside compressor.

8. What is entropy? Write the general equation.

Ans.
Entropy is the measure of a system’s thermal energy per
unit temperature that is unavailable for doing
useful work. dS=dQ/dT.

9.  What is resilience of a material?

Ans.
Resilience is the ability of a material to absorb energy when it
is deformed elastically.

2
 10. What is the material of a journal bearing?
Ans.
Copper based Tin Bronzes

11. What is the basic difference between a petrol and a diesel engine?
Ans.
In petrol engines spark plugs are present to create ignition while in
diesel engines fuel injectors are present to supply fuel.

12. What is the compression ratio of a petrol engine?

Ans.
14:1

13. What are the different positive displacement pumps?

Ans.
Rotary pumps, reciprocating pumps, linear pumps etc.

14. What are the different negative displacement pumps?

Ans.
There is nothing called negative displacement pumps

15. What is the electrical resistance of a lamp with the following

rating 100Watts-220 Volts?
Ans.
4840 ohms

16. What is a Gear pump? Where is it used? What is its purpose?

Ans.
Gear pump is a positive displacement pump. It is used in order to
pump highly viscous fluids like oil. Purpose of gear pump is to solve
the problem of pumping highly viscous fluids with some ease.

3
17. What is a vane pump?
Ans.
A rotary vane pump is a positive-displacement pump that consists of
vanes mounted to a rotor that rotates inside a cavity. In some cases,
these vanes can have variable length and/or be tensioned to maintain
contact with the walls as the pump rotates.

18. Explain the factors that determine the volumetric efficiency of a

vane pump and gear pump.
Ans.
Viscosity, pressure, wear, and slip

19. Which pump is used for circulating water through the engine?
Ans.
Centrifugal pump

20. For Brake Cylinder why can't we use water instead of oil?
Ans.
More viscous the fluid, lesser effort will be required to transfer the
power from the legs to the brake bushes. Viscosity of oil>viscosity of
water.

21. Have you heard of notches? If yes explain their significance

Ans.
Notches are used in materials characterization to determine fracture
mechanics related properties such as fracture toughness and rates of
fatigue crack growth.

22. Which are the pumps that are used at home to pump water?
Ans.
Centrifugal pumps

4
23. When the pump is running if we close the delivery valve what will
happen?
Ans.
Due to high pressure the pump will burst.

24. Explain what do you mean by Water Hammer Effect? When does it
occur?

Ans.
Due incomplete balancing of reciprocating masses, there will be a
vertical component of force which is unbalanced. This causes hammer
blow.

25. What are the different types of pumps? Explain the significance of
each one
Ans.
Pumps can be classified by their method of displacement into positive
displacement pumps, impulse pumps, velocity pumps, gravity
pumps, steam pumps and valve less pumps. There are three basic
types of pumps: positive displacement, centrifugal and axial-flow
pumps. In centrifugal pumps the direction of flow of the fluid changes
by ninety degrees as it flows over impeller, while in axial flow pumps
the direction of flow is unchanged.

26. Which has more compression ratio? Diesel Engine or Petrol

Engine?
Ans.
Diesel engines

27. What is non-destructive testing? What are the different types of

non-destructive testing?
Ans.

5
Nondestructive testing (NDT) is a wide group of analysis techniques
used in science and technology industry to evaluate the properties of
a material, component or system without causing damage.

28. Can you elaborate on radiography as a method of non-destructive

testing? When would you go for radiography?
Ans.
Industrial radiography is a method of non-destructive testing where
many types of manufactured components can be examined to verify
the internal structure and integrity of the specimen. Industrial
Radiography can be performed utilizing either X-rays or gamma rays.
Both are forms of electromagnetic radiation. The difference between
various forms of electromagnetic energy is related to the wavelength.
X and gamma rays have the shortest wavelength and this property
leads to the ability to penetrate, travel through, and exit various
materials such as carbon steel and other metals.

29. What is meant by ultrasonic testing?

Ans.
Ultrasonic testing (UT) is a family of non-destructive testing
techniques based on the propagation of ultrasonic waves in the
object or material tested. In most common UT applications, very
short ultrasonic pulse-waves with center frequencies ranging from
0.1-15 MHz, and occasionally up to 50 MHz, are transmitted into
materials to detect internal flaws or to characterize materials. A
common example is ultrasonic thickness measurement, which tests
the thickness of the test object, for example, to monitor pipework
corrosion.

30. What are the differences between jigs and fixtures?

Ans.
The key difference between Jigs and Fixtures is that a jig is a type of

6
tool used to control the location or motion of another tool. On the
other hand, a fixture is a support or work holding device used to hold
work in place.

31. What are the different degrees of freedom?

Ans.
Translation along 3 axes and rotation about 3 axes.

32. Explain the factors that determine the volumetric efficiency of a

vane pump and gear pump.
Ans.
Viscosity, pressure, wear, slip

33. We know about Internal Combustion(IC) Engine. Is there anything

called the External Combustion Engine?

Ans.
An external combustion engine (EC engine) is a heat engine where a
working fluid, contained internally, is heated by combustion in
an external source, through the engine wall or a heat exchanger. The
fluid then, by expanding and acting on the mechanism of the engine,
produces motion and usable work.

34. What is displacement volume?

Ans.
The volume of displaced fluid is equivalent to the volume of an object
fully immersed in a fluid or to that fraction of the volume below the
surface of an object partially submerged in a liquid.

35. What are the basic differences between kaizen and kanban?
Ans.
Kanban is a term that literally means visual card or sign. This system
was originally used as a way to monitor assembly lines in a production
7
environment, but the term has been broadened to refer to an overall
signaling system that has been adopted by many software
organizations as a part of Agile project management. As we shall see,
it is particularly useful in the visualization of pull scheduling systems,
where it is used as an aid to maintaining optimal system throughput.
Kaizen simply means change for the good. Its use reflects a philosophy
that is based upon attempting to make continuous improvement in all
areas of work activities. A key part of optimizing change for the
better is to eliminate waste and excess in the system. In many ways
adopting Kaizen is less process oriented than implementing Kanban,
but there are many overlaps as well as dissimilarities in the two
approaches.

36. Provide the detailed classification of welding techniques

Ans.
a) Arc Welding
SMAW (Shielded Metal Arc Welding or stick Welding)
GMAW (Gas Metal Arc Welding or MIG welding)
GTAW (Gas Tungsten Arc Welding or TIG Welding)
SAW (Submerged Arc Welding)
FCAW (Flux Cored ARC Welding)
PAW (Plasma Arc Welding)
Carbon Arc Welding
Stud Welding
b) Resistance Welding
Resistance Spot Welding
Resistance Seam Welding
Resistance Projection Welding
Flash Welding
c) Oxyfuel welding
d) Others
Electron beam welding
Laser beam Welding
SOLID STATE WELDING: In solid state welding, joining is done by the
application of pressure alone or a combination of pressure and heat.
Normally the base metal is not reached to the melting point, if heat is
8
 applied to obtain the coalescence and filler metal is not used. Some of
the solid state welding processes are:
1. Diffusion welding (DFW)
2. Friction welding (FRW)
3. Ultrasonic welding (USW)
4. Cold Welding
5. Forge welding
6. Explosion welding (EXW)

37. Explain the differences between TIG and MIG welding?

9
38. Why does TIG welding stands out compared to others ?
Ans.
It doesn't require any flux and this is because of the inert gas shields
molten metal. Therefore, there are no hassles with the slag and
inclusion of slag. This welding machine will easily provide you with
high quality and strong welding finishes.

39. What are the different types of weld joints?

Ans.
1. Butt joint
2. Corner joint
3. Lap joint
4. Tee joint and
5. Edge joint

40. Which is more efficient? Lap or Butt joint? Why is it so?

Ans.
Lap joint is more efficient

41. Why do we go for welding instead of nuts and bolts?

Ans.
Nuts and bolts cause stress concentration, hence we prefer welding
over nuts and bolts

42. What is a fillet weld? Draw a fillet weld joint and mark the parts
Ans.
Fillet welding refers to the process of joining two pieces
of metal together whether they be perpendicular or at an angle.

10
43. In a manufacturing industry what is the significance of the Five S ?
Ans.
Sort, set in order, shine, standardize and sustain. This brings in
discipline in the operations and reduces wastage of time and
confusions.

44. What are the basic techniques that can be used for the
optimization of a manufacturing plant?
Ans.
Implementation of methodologies like six sigma, grey-Taguchi
methods, 7 quality tools, 5S techniques can optimize the given plants.

45. How do we prepare the edges before welding?

Ans.
Edge preparation consists of removing material along edges of metal
surfaces. You must prepare edges for welding when parts and
assemblies require certain strength. To achieve
full welding penetration, you must cut the edges of the metal.

46. Could you please draw the characteristic curve of an engine?

Ans.
11
47. When the engine is under full load condition, does it mean that it
is running at maximum rpm?
Ans.
If it is under full load condition, it is running in a minimum RPM

49. What is the function of a turbocharger in an engine?

Ans.
Turbocharger is used to supply compressed air or air-fuel mixture
through in the inlet manifold so that work done by the piston to
compress the air or the air-fuel mixture reduces.

50. What is vane angle?

Ans.
The vane angle βs determines the fluid flow direction in an impeller
(also see Vane, Vane cascade). On centrifugal pumps it is defined
as the angle between the chord c and the circumferential direction
u.

51. How are turbochargers placed in an engine?

Ans.
12
The turbocharger is bolted to the exhaust manifold of the engine. The
exhaust from the cylinders spins the turbine, which works like a gas
turbine engine which in turn is connected by a shaft to the
compressor located between the air filter and the intake manifold.

52. What do you mean by crevice flow?

Ans.
The engine combustion chamber is connected to several
small volumes usually called crevices because of their
narrow entrances.
Gas flows into and out of these volumes during the
engine operating cycle as the cylinder pressure
and volume change.

52. Where is the oil located in an engine?

Ans.
The oil poured in the top of the engine goes through many
paths eventually arriving in the bottom oil pan, often called
the sump, where the drain plug is located.

53. What are piston rings?

Ans.
A piston ring is a metallic split ring that is attached to the
outer diameter of a piston in an internal combustion engine
or steam engine. The main functions of piston rings in engines
are:
Sealing the combustion chamber so that there is minimal loss
of gases to the crank case. 

54. What is lubricating rings?

Ans.
A ring oiler or oil ring is a form of oil-lubrication system for
bearings. 
13
 55. Which of the above two rings is arranged closest to the
combustion chamber?
Ans.
Piston ring

56. What are the differences between an IC Engine and an EC

Engine?
Ans.
Combustion: The main difference is where the combustion
takes places. In IC engines fuel combustion takes place
inside the cylinder, whereas in EC engines it takes place
outside the engine cylinder.
The temperature and pressure in an IC engines is much
higher than those of EC engines.
IC engines are made of materials that are better resistant
to heat and pressure than in EC engines.
In IC engines the piston is directly connected to connecting
rod, whereas in an EC engine there is a stuffing box.
Efficiency is higher for IC engines.
Boilers are required for EC engines to store water, which is
to be converted to steam. But IC engines require only a
much smaller tank to store fuel.

57. What is blow-by?

Ans.
Blow-by is unwanted leakage of gas under pressure,
such as that from a piston or its sealing rings.
The blow-by that occurs when too much pressure from
the combustion chamber leaks into the crankcase needs
to escape somewhere.

58. What is blow-by?

Ans.
Blow-by is unwanted leakage of gas under pressure, such as
that from a piston or its sealing rings. The blow-by that
occurs when too much pressure from the combustion
14
 chamber leaks into the crankcase needs to escape somewhere.

59. What are the differences between a 2-stroke engine and a 4-

stroke engine?
Ans.
A 2 stroke engine has ports which make its design much
simpler whilst a 4 stroke engine appears to have a
complicated design due to its valve mechanism.
4 stroke engines are comparatively heavier in contrast to 2
stroke engines.
The top side of the piston on a 4 stroke engine is flat whilst a
bump or protuberance may be needed on the top side of a 2
stroke engine’s piston.
Whilst a 2 stroke engine becomes loud when operating, a 4
stroke engine makes less noise in comparison.
A 4 stroke engine completes 2 rotations of the crankshaft
after finishing one cycle, where a 2 stroke engine completes
only 1.
With a 4 stroke engine, power is produced once every 4
strokes of the piston whilst power is produced every 2 strokes
in a 2 stroke engine.
Regular addition of oil is required for a 2 stroke engine, unlike
a 4 stroke engine.
With a 2 stroke engine, the air-fuel mixture enters through the
inlet port and travels to the combustion chamber, passing
through the crankcase. The mixture on a 4 stroke engine, on
the other hand, remains in the combustion chamber only.

60. What is the purpose of the idle wheel in sugarcane crushing

machine?
Ans.
A gear wheel placed between two other gears to transmit motion
from one to the other. It does not alter the speed of the output,
15
 but it does alter the direction it turns. It is used to ensure that the
rotation of two gears is the same. An idler gear is placed between
two gears

61. What is circlip?

Ans.
It’s a type of fastener or retaining ring consisting of a semi
flexible metal ring with open ends which can be snapped
into place, into a machined groove on a dowel pin or other
part to permit rotation but to prevent lateral movement.

62. Why is the cross-section of rail an I-section?

Ans.
The I section of railway tracks and many beams used in
constructions is because

 It reduces weight.  
 The sagging (bending) of tracks as well as the stresses
generated  when loading is applied are reduced.
 The Amount of material used is reduced by a huge amount
and there is no significant difference in manufacturing
Methods of Rectangle Beam or I-shaped Beam.
The I-shaped cross sections have almost same moment of Inertia as
rectangular Beam but there is significant decrease in
weight and hence amount of material used in turn the cost
of manufacturing.

63. How does differential gear work in automobiles?

Ans.
Differential gear, in automotive mechanics, gear arrangement
that permits power from the engine to be transmitted to a pair
of driving wheels, dividing the force equally between them but
permitting them to follow paths of different lengths, as
when turning a corner or traversing an uneven road.
16
 When the car is traveling straight, both wheels travel at the
same speed. Thus, the free-wheeling planet pinions do not
spin at all. Instead, as the transmission shaft turns the
crown wheel, the rotary motion is translated directly to the
half-shafts, and both wheels spin with the angular velocity
of the crown wheel (they have the same speed).
When the car is turning, the wheels must move at different
speeds. In this situation, the planet pinions spin with
respect to the crown wheel as they turn around the sun
gears. This allows the speed of the crown gear to be
delivered unevenly to the two wheels.

64. What is meant by Investment casting ?

Ans.
Investment casting is an industrial process based on lost-
wax casting, one of the oldest known metal-forming
techniques. The term "lost-wax casting" can also refer to
modern investment casting processes. 

65. How does a turbo-charger work ?

Ans.
The turbocharger on a car applies a very similar principle to
a piston engine. It uses the exhaust gas to drive a turbine.
This spins an air compressor that pushes extra air (and
oxygen) into the cylinders, allowing them to burn more
fuel each second.

66. What is the use of draft in casting ?

Ans.
During the cooling process, the castings will shrink
towards the core at an acceptable rate. This is the reason
why drafts are higher on the inner surfaces of the die. To
17
 avoid high pressure in castings, the inside corners must be
protected with fillets.

67. How do you use software for surface modelling ?

Ans.
CAD software packages use two basic methods for the
creation of surfaces. The first begins with construction
curves (splines) from which the 3D surface is then swept
(section along guide rail) or meshed (lofted) through.The
second method is direct creation of the surface with
manipulation of the surface poles/control points.
From these initially created surfaces, other surfaces are
constructed using either derived methods such as offset or
angled extensions from surfaces; or via bridging and
blending between groups of surfaces.

68. How is core used in Casting ?

Ans.
Core is a part which is inserted in casting to make internal
features such as holes or hollow structures.

69. Explain the following heat treatment process : Annealing,

Normalizing and Hardening
Ans.
Annealing, treatment of a metal or alloy by heating to a
predetermined temperature, holding for a certain time,
and then cooling to room temperature to
improve ductility and reduce brittleness.
Normalizing involves heating a material to an elevated
temperature and then allowing it to cool back to room
temperature by exposing it to room temperature air after
it is heated. 
Hardening is a metallurgical metalworking process used to

18
 increase the hardness of a metal. 

70. Draw the shear force diagram and bending moment diagram

for Cantilever Beam ?

71. What are the basic classification of IC Engines and EC engines?

Ans.
Classification of IC Engines:
Reciprocating
Rotary
Continuous combustion
Classification of EC Engines
Single phase
Dual phase

19
 72. Given an I-section to design how would you use Pro-E or
CATIA to design the system
Ans.
Draw half of the section about the axis and mirror the
feature about that axis to make a symmetric copy.
73. What are the cycles that you have studied in thermal
engineering ?
Ans.
i. Vapor absorption refrigeration cycle
ii. Gas cycle
iii. Reversed carnot/ Brayton cycle
iv. Rankine cycle

74. Draw the stress-strain diagram for mild steel and carbon steel
Ans.

75. Explain the working of Otto cycle and Diesel cycle

Ans.
OTTO CYCLE

Process 1 to 2: During this phase the piston will be

drawn up, so it can compress the fuel-air mixture that
entered the chamber. The compression causes the

20
 mixture to increase slightly in pressure and
temperature—however, no heat is exchanged. In
terms of thermodynamics, this is referred to as an
adiabatic process. When the cycle reaches point 2,
that is when the fuel is met by the spark plug to be
ignited.

Process 2 to 3: This is where combustion occurs due to the ignition

of fuel by the spark plug. The combustion of the gas is
complete at point 3, which results in a highly
pressurized chamber that has a lot of heat (thermal
energy). In terms of thermodynamics, this is referred
to as an isochoric process.

Process 3 to 4: The thermal energy in the chamber as a result of

combustion is used to do work on the piston—which
pushes the piston down—increasing the volume of
the chamber. This is also known as the power stoke
because it is when the thermal energy is turned into
motion to power the machine or vehicle.

Process 4 to 1 and exhaust phase): From process 4 to 1, all waste

heat is expelled from the engine chamber. As the heat
leaves the gas, the molecules lose kinetic energy
causing the decrease in pressure.[6] Then the exhaust
phase occurs when the remaining mixture in the
chamber is compressed by the piston to be
"exhausted" out, without changing the pressure.

DIESEL CYCLE

21
 Process 1-2: Isentropic Compression
In this process, the piston moves from Bottom Dead
Centre (BDC) to Top Dead Centre (TDC) position. Air is
compressed isentropically inside the cylinder.
Pressure of air increases from p1 to p2, temperature
increases from T1 to T2, and volume decreases from
V1 to V2. Entropy remains constant (i.e., s1 = s2). Work is
done on the system in this process (denoted by Win in
the diagrams above).

Process 2-3: Constant Pressure Heat Addition

In this process, heat is added at constant pressure
from an external heat source. Volume increases from
V2 to V3, temperature increases from T2 to T3 and
entropy increases from s2 to s3.

Process 3-4: Isentropic Expansion

Here the compressed and heated air is expanded
isentropically inside the cylinder. The piston is forced
from TDC to BDC in the cylinder. Pressure of air
decreases from p3 to p4, temperature decreases from
T3 to T4, and volume increases from V3 to V4. Entropy
remains constant (i.e., s3 = s4). Work is done by the
system in this process (denoted by Wout in the p-V and
T-s diagrams above).
Process 4-1: Constant Volume Heat Rejection
In this process, heat is rejected at constant volume
(V4 = V1). Pressure decreases from P4 to P1,
temperature decreases from T4 to T1 and entropy
decreases from s4 to s1.

a. What are all the post-processing after the

manufacture of a product?
Ans:-Natural post-processing
Standard post-processing
Standard and External post-processing
22
 Primed post-processing

b. What are the differences between Forging & Casting?

Ans:- Casting is the process where metal is heated
until molten. While in the molten or liquid state
it is poured into a mold or vessel to create a desired
shape. Forging is the application of thermal and
mechanical energy to steel billets or ingots to cause
the material to change shape while in a solid state.

81. How will you start an automobile engine?

Ans:- When the key is turned, the starter motor "turns
the engine over," which means it turns the crankshaft
which in turn gets the pistons moving in the cylinders.
This starts the engine cycle. Air and fuel is drawn into
the cylinders, it is compressed and the then the spark
plugs fire. This begins combustion.

82. What is non-destructive testing?

Ans:-Nondestructive testing is a wide group of
analysis techniques used in science and technology
industry to evaluate the properties of a material,
component or system without causing damage. 

83. What are the differences between jigs and fixtures ?

Ans:-
Jig:
1) A device which holds and locates a work piece and
guides and controls one or more cutting tools, is
called a jig.
2) The holding of work and guiding of the tools are
such that they are located in true positions relative to
each other.

23
 3) A jig comprises of of a plate, structure, or box made
of metal or non-metal having provisions for holding
the components in identical positions one after the
other and then guiding the tool in correct position on
the work.
Fixture:
1) A fixture may be defined as a device which holds
and locates a work piece during an inspection or for a
manufacturing operation. It does not guide the tool.
2) It comprises of specially designed work holding
devices, which are clamped on the machine table to
hold the work in position.
3) The tools are set at the required position on the
work by using the gauges or by manual adjustment.

84. What are the colors of the objects while constraining

in ProE ?
Ans.
Dark Blue, Green, White etc.
85. What is the use of flywheel in an automobile?
Ans.
It stores and delivers energy when there is a
fluctuation in speed or energy in the engine. It
reduces the fluctuations in energy.
86. What is meant by user-defined system in ProE?
Ans.
User Defined Features (UDFs) are ProE objects that
you can create to speed up the creation of common
features you use or to give your features more
parameters.
87. What will happen if petrol is put into diesel engine and
diesel is put into petrol engine ?
Ans.
When diesel is put into a petrol engine, the diesel does

24
 not evaporate like petrol does and there will be no
spark.
88. What is Computer Integrated Manufacturing(CIM) &
Computer Aided Manufacturing(CAM) ?
Ans.
Computer-integrated manufacturing is the
manufacturing approach of using computers to control
entire production process. This integration allows
individual processes to exchange information with
each other and initiate actions.
Computer-aided manufacturing also known as
Computer-aided Modeling or Computer-aided
Machining is the use of software to control machine
tools and related ones in the manufacturing of work
pieces.
89. What are the packages used for CIM and CAM ?
Ans.
CIM – FMS (flexible manufacturing system), ASRS
(automated storage and retrieval system) AGV
(automated guided vehicle) Robotics, Automated
conveyance systems
CAM - Fusion 360, Solid edge, Solidworks CAM

90. What are the things that you look into when you are
designing a component or product?
Ans.

Aesthetics,Ergonomics,Materials,Manufacture,Modulari
ty,Sustainability,Protection,Packaging & Assembly

91. What are the different patterns available in ProE ?

25
 Ans.

Dimension pattern, Axis pattern, Direction, Fill option,

Table pattern, Curve pattern, Point pattern

92. What do you mean by Reverse Engineering?

Ans.
Reverse engineering, also called back engineering, is
the process by which a man-made object is
deconstructed to reveal its designs, architecture, or to
extract knowledge from the object; similar to scientific
research, the only difference being that scientific
research is about a natural phenomenon

93. You have a drawing of a screw with some basic

parameters. You want to make 100 drawing of the
screw with variable parameters. Is that possible in ProE
?
Ans.
Yes, it’s possible.

94. Details about carbon-iron diagram?

Ans.
The iron-carbon diagram (also called the iron-carbon
phase or equilibrium diagram) is a graphic
representation of the respective microstructure states
depending on temperature (y axis) and carbon content
(x axis). There are different microstructures in the solid
state:
Ferrite: contains hardly any carbon.
Ferrite + perlite: As the carbon concentration
increases, cementite is released. This becomes a new

26
 microstructure constituent and forms a ferrite-perlite
microstructure.
Perlite: As the carbon concentration increases further,
the ferrite fraction reduces steadily. From a carbon
concentration of 0.8…0.85 %, only perlite is left.
Perlite + cementite: If the carbon concentration
continues to increase, cementite deposits on the grain
boundaries of the perlite. If examined under a
microscope, these thickened grain boundaries can be
seen. Cementite is a very hard and brittle
microstructure component. Therefore, in many steel
grades the cementite separation must be prevented.
This is done by fast cooling. If the formation of
cementite is not prevented, material can spall under
mechanical loads.

95. Types of gears and some real life applications?

Ans.
Spur Gear - Spur gears transmit power through shafts that
are parallel.
Helical Gear -Helical gears have teeth that are oriented at
an angle to the shaft, unlike spur gears which are parallel.
Double Helical Gear -Double helical gears are a variation of
helical gears in which two helical faces are placed next to
each other with a gap separating them.
Herringbone Gear - Herringbone gears are very similar to
the double helical gear, but they do not have a gap
separating the two helical faces.
Bevel Gear - Bevel gears are most commonly used to
transmit power between shafts that intersect at a 90
degree angle.
Worm Gear - Worm gears transmit power through right

27
 angles on non-intersecting shafts.
Hypoid Gear - Hypoid gears look very much like a spiral
bevel gear but they operate on shafts which do not
intersect, which is the case with a spiral bevel gear.

97. Name few casting methods?

Ans.
1. Conventional moulding Processes: - Green Sand
moulding, Dry Sand moulding, Flask less moulding
2. Chemical Sand moulding Processes: - Shell
moulding/Shell cast moulding, Sodium Silicate
moulding, No-Bake moulding
3. Permanent mould Processes: - Gravity Die casting,
Low and High Pressure Die Casting
4. Special Casting Processes: - Lost Wax or Investment
mold casting, Ceramics Shell moulding, Evaporative
Pattern Casting, Vacuum Sealed moulding, Centrifugal
Casting

98. Name few pattern making methods?

Ans.
Single piece pattern, Split pattern or two piece pattern,
multiple piece pattern, Gated pattern, Match plate
pattern, Cope and drag pattern, loose piece pattern,
Follow board pattern, Sweep pattern, Skeleton pattern

99. Name few types of refrigeration cycles?

Ans.
Vapor compression refrigeration cycle, Vapor
absorption refrigeration cycle, Gas cycle, Reversed
carnot/ Brayton cycle , Rankine cycle

28
 100. What are the types of gear transmissions?
Ans.
Automatic Transmission (AT):-This is a transmission
that uses a torque converter, planetary gear set and
clutches or bands to shift through a vehicle's forward
gears automatically. Some automatics allow the driver
a limited amount of manual control over the vehicle
(aside from choosing a forward, reverse or neutral
mode) -- for example allowing the driver to control
upshifts and downshifts by utilizing buttons or paddles
on the steering wheel or the gear selector. Common
names for such transmissions are "shiftable
automatic," "Tiptronic" and "autostick." To learn more,
see Automatic Transmissions: What Makes Them Work.
Manual Transmission (MT):-With a manual
transmission, the driver selects all gears manually using
both a movable gear selector and a driver-operated
clutch. This type of transmission is also known as a
"stick shift" or a "standard" transmission. See Manual
Transmission Basics for more information.
Automated Manual Transmission (AM):-Like a manual
transmission, an automated manual also employs a
mechanical clutch; however, the action of the clutch is
not controlled by the driver via the clutch pedal but
rather is automated using electronic, pneumatic or
hydraulic controls. Sometimes referred to as a "Direct
Shift Gearbox" ("DSG") or a "Sequential Manual
Gearbox" ("SMG"), this transmission allows for either
fully automatic forward gear shifts or manual shifts
through the gear selector or through buttons or
paddles on the steering wheel.
Continuously Variable Transmission (CVT):-This

29
 transmission has a continuously variable drive ratio (as
opposed to conventionally stepped gear ratios) and
uses belts, pulleys and sensors rather than gears to
maintain a steady acceleration curve with no pauses
for gear changes. Because of this, a CVT can keep the
engine in its optimum power range, thereby increasing
efficiency and gas mileage. You can get more
information from CVT Enters the Mainstream.

101. Different welding techniques?

Ans.
• Shielded metal arc welding (SMAW), also known as
"stick welding."
•Gas tungsten arc welding (GTAW), also known as TIG
(tungsten, inert gas).
• Gas metal arc welding (GMAW), also known as MIG
(metal, inert gas).
• Flux-cored arc welding (FCAW), very similar to MIG.
•Submerged arc welding (SAW), usually called Sub
Arc.
•Electros lag welding (ESW), a highly productive
process for thicker materials.

102. Different manufacturing processes?

Ans.
Some of them are casting, rolling, extrusion, welding,
turning, milling, drilling, boring.

103. Explain Profile of gears?

Ans.
The involute gear profile is the most commonly used
system for gearing today, with cycliod still used for

30
 some specialties such as clocks. In an involute gear, the
profiles of the teeth are involutes of a circle. (The
involute of a circle is the spiraling curve traced by the
end of an imaginary taut string unwinding itself from
that stationary circle called the base circle.)
104. Manufacturing process?
Ans.
There are several different processes involved during
manufacturing and here are a few of them casting,
rolling, extrusion, welding, turning, milling, drilling,
boring etc.

105. Different metals used in car?

Ans.
Aluminum, Mild steel, Cast iron and may more.

106. Basic difference between pearlite,martensite?

Ans.
Pearlite transformation occurs by diffusion process
martensite transformation occurs by shear process

107.What is spheroisdising?
Ans.
Spheroidizing is a form of heat treatment for iron-
based alloys, commonly carbon steels, in order to
convert them into ductile and machinable alloys.

108. Casting process?

Ans.
Casting is a process in which molten metal is poured
into a mould cavity and let to solidify to form into a
required shape.

31
 109. Types of loading in flywheel?
Ans.
Static Loading and Dynamic loading.

110. In cold forging, the metal is heated to.

Less than recrystallization temperature of the metal.

111. Helix angle in spur gear

Helix angle is the angle between any helix and an axial
line on its right, circular cylinder or cone.

112. Change in center distance, what happens to the

pressure angle?
The involute gear profile increase in the center-to-
center distance leads to increase in pressure angle.

113. Right helical gears mess with – type of helical gear?

Left helical gear.

114. V-belt drives are used for – center distance.

Lesser than 1m.

115. Explain Corrosion types

Ans.
• There are five general types of corrosion:
• Galvanic
• Stress cracking
• General
• Localized
• Caustic agent corrosion.

32
 116. Explain Rankine cycle
Ans.
The Rankine cycle is an idealized thermodynamic cycle
of a heat engine that converts heat into mechanical
work while undergoing phase change. Friction losses in
each of the four components are neglected in an
idealized cycle.

117. Different manufacturing processes

Ans.
Casting, rolling, extrusion, welding, turning, milling,
drilling, boring etc.

118. What is knocking?

Ans.
Knocking (also knock, detonation, spark knock, pinging
or pinking) in spark ignition internal combustion
engines occurs when combustion of some of the
air/fuel mixture in the cylinder does not result from
propagation of the flame front ignited by the spark
plug, but one or more pockets of air/fuel mixture
explode outside the envelope of the normal
combustion front.

119. What is detonation?

Ans.
Detonation — generally caused by fuel with a low
octane rating — is the tendency for the fuel to pre-
ignite or auto-ignite in an engine's combustion
chamber. This early (before the spark plug fires)
ignition of fuel creates a shock wave throughout the

33
 cylinder as the burning and expanding fuel-air mixture
collides with the piston that is still traveling towards
top-dead-center. The resulting knock or ping is the
sound of the pistons slamming against the cylinder
walls.

120.What is conduction, convection….examples

Ans.
•Conduction: one hot body and one cold body brought
in contact
• Convection: hot tea let to cool with air
•Radiation: any object above 0 K

121. What is butanol…chemical formula….applications

Ans.
Butanol is primarily used as a solvent, as an
intermediate in chemical synthesis, and as a fuel. It is
sometimes also called bio butanol when produced
biologically and petro butanol when produced from
petroleum; those two names refer to the same
substance, but highlight their different origins.
C4H10O.

122. What is CNC programming?

Ans.
Manufacturers to create programed instructions for
computers to control a machine tool utilize CNC
programming (Computer Numerical Control
Programming). CNC is highly involved in the
manufacturing process and improves automation as
well as flexibility.

34
 123.Manufacturing and Thermodynamics
Ans.
Manufacturing processes include places where a lot of
heat is produced for example like in processes like
drilling, milling, boring etc. So thermodynamics is
considered for the design of manufacturing processes.

124.What is slenderness ration?

Ans.
The ratio of the effective length of a column to the
least radius of gyration of its cross section is called the
slenderness ratio (sometimes expressed with the
Greek letter lambda, λ).

125.What is knocking?
Ans.
Knocking (also knock, detonation, spark knock, pinging
or pinking) in spark ignition internal combustion
engines occurs when combustion of some of the
air/fuel mixture in the cylinder does not result from
propagation of the flame front ignited by the spark
plug, but one or more pockets of air/fuel mixture
explode outside the envelope of the normal
combustion front.

126.Spring constant and different springs.

Ans.
• Different types of mechanical springs are
• Mechanical compression springs
• Mechanical extension springs
• Mechanical torsional springs
• Mechanical conical tapered springs.

35
 127. What does a refrigerator do?
Ans.
Using an evaporator, heat is absorbed from the given
object. This cools the object and hence this what a
refrigerator does.

128.Advantages of a Reaction turbine

Ans.
Many capital savings can be done.

129.Where do you experience water hammer?

Ans.
Water hammer may occur when a dishwasher, washing
machine or toilet shuts off water flow. The result may
be heard as a loud bang, repetitive banging (as the
shock wave travels back and forth in the plumbing
system), or as some shuddering.

130. Euler’s Number

Ans.
The number e is a mathematical constant that is the
base of the natural logarithm: the unique number
whose natural logarithm is equal to one. It is
approximately equal to 2.71828, and is the limit of ⁿ as n
approaches infinity, an expression that arises in the
study of compound interest.

131. Basic Mechanical Engineering – Spring Constant &

Different Springs
Ans.
Here are different types of mechanical springs

36
 • Mechanical compression springs
• Mechanical extension springs
• Mechanical torsional springs
• Mechanical conical tapered springs.

132.What is water hammering effect

Ans.
Water hammer is a pressure surge or wave caused
when a fluid (usually a liquid but sometimes also a gas)
in motion is forced to stop or change direction
suddenly (momentum change). As soon as steam
leaves the boiler, it starts losing heat. ... This gives rise
to the phenomenon of water hammer.

133.Turbines, pumps
Ans.
Turbine
A turbine is a rotary mechanical device that extracts
energy from a fluid flow and converts it into useful
work. The work produced by a turbine can be used for
generating electrical power when combined with a
generator.
Pumps
Vacuum pumps are used to provide a vacuum filtering
on flue gas desulphurization system before the gases
are emitted through the stack. This process removes
water vapor from gypsum and other ashes that can be
recovered as dry materials.

134.What is distributor?
Ans.
The distributor is a device in a petrol engine for passing

37
 electric current to each spark plug in turn.

135.Function of receiver in a compressor?

Ans.
The receiver tank acts as a reservoir of compressed air
for peak demands. The receiver tank will help remove
water from the system by allowing the air a chance to
cool. The receiver tank minimizes pulsation in the
system caused by a reciprocating compressor or a
cyclic process downstream.

136. Spark plug

Ans.
A spark plug is a device for delivering electric current
from an ignition system to the combustion chamber of
a spark-ignition engine to ignite the compressed
fuel/air mixture by an electric spark, while containing
combustion pressure within the engine.

137.Draft tube
Ans.
Draft Tube is a diverging tube fitted at the exit of
runner of turbine and used to utilize the kinetic energy
available with water at the exit of runner. '. This draft
tube at the end of the turbine increases the pressure of
the exiting fluid at the expense of its velocity.

138. Difference between axial and radial compressor

Ans.
A radial compressor can usually generate higher
pressure in a single stage so it's usually simpler, while
an axial compressor is easier to stack in multiple stages

38
 to get much higher pressure ratios.

139. Dimensionless constants (Reynolds no etc)

Ans.
Some important dimensionless numbers used in fluid
mechanics and their importance is explained below.
• Reynolds Number
• Froude Number
• Weber Number
• Mach Number
• Euler’s Number

140. Flow over bodies eg (how swing occurs in a cricket

ball)
Ans.
Swing of cricket ball is mainly due to the asymmetry of
flow on two sides of the ball. When ball is new, it is
smooth on both sides. To achieve outswing, ball is
bowled such that seam is angled towards first/second
slip. Therefore, flow is tripped into turbulent on seam
side

141. Penstock
Ans.
A penstock is a sluice or gate or intake structure that
controls water flow, or an enclosed pipe that delivers
water to hydro turbines and sewerage systems. The
term is inherited from the earlier technology of
millponds and watermills.

142.What is the difference between static viscosity and

dynamic viscosity?

39
 Ans.
Dynamic viscosity is the quantitative expression of
fluid's resistance to flow, while Kinematic viscosity is
the ratio of the fluid's viscous force to the inertial
force. 2. Dynamic viscosity is symbolized by either 'µ'
or 'n', while Kinematic viscosity is mathematically
symbolized by 'v'.

143.What is the velocity of fluid out of hole in the tank?

Ans.
v=sqrt(2gh)
g=gravitational acceleration
h=height of the tank

144. What does Back Rake Angle mean?

Ans.
Back rake angle is the angle between the face of the
single point cutting tool and a line parallel with base of
the tool measured in a perpendicular plane through
the side cutting edge. ... Back rake angle helps in
removing the chips away from the work piece.

145.The working mechanism of a shaper?

Ans.
The ram holding the tool reciprocates over the work
piece and metal is cut during the forward stroke called
a cutting stroke and. No metal is cut during its return
stroke is called an Idle stroke. The feed is given at the
end of the cutting stroke.

40
 146. What is Quick-Return Mechanism and explain the
working?
Ans.
A quick return mechanism is an apparatus to produce a
reciprocating motion in which the time taken for travel
in return stroke is less than in the forward stroke. It is
driven by a circular motion source (typically a motor of
some sort) and uses a system of links with three
turning pairs and a sliding pair.

147.What is the hardness range of mild steel and yield-

strength?
Ans.
For most steels, indentation hardness correlates with
yield strength, and therefore a hardness test can be
carried out as an economical alternative to tensile
testing. Like tensile strength, yield strength is
measured in Pascal’s (Pa) or megapascals (MPa). Mild
steel as an approximate yield strength of 250MPa

148. Bernoulli’s principle

Ans.
In fluid dynamics, Bernoulli's principle states that an
increase in the speed of a fluid occurs simultaneously
with a decrease in static pressure or a decrease in the
fluid's potential energy.

149. Third angle projection.

Ans.
Third Angle projection is a method of orthographic
projection, which is a technique in portraying a 3D

41
 design using a series of 2D views.

150. What is Development of solid. Explain with regard to a

frustum?
Ans.
In geometry, a frustum (plural: frusta or frustums) is
the portion of a solid (normally a cone or pyramid) that
lies between one or two parallel planes cutting it. A
right frustum is a parallel truncation of a right pyramid
or right cone.
In computer graphics, the viewing frustum is the three-
dimensional region, which is visible on the screen. A
clipped pyramid forms it; in particular, frustum culling
is a method of hidden surface determination.
In the aerospace industry, a frustum is the fairing
between two stages of a multistage rocket (such as
the Saturn V), which is shaped like a truncated cone.

151. Max shear stress for a plane inclined to the axis of a

work piece.
Ans.
Max shear stress=sqrt((normal stress along x +normal
stress along y)/2)

152.Feeler gauge uses?

Ans.
A feeler gauge is a tool used to measure gap widths.
Feeler gauges are mostly used in engineering to
measure the clearance between two parts.

153.What is caster angle?

42
 Ans.
The caster angle or castor angle is the angular
displacement of the steering axis from the vertical axis
of a steered wheel in a car, motorcycle, bicycle, other
vehicle or a vessel, measured in the longitudinal
direction.

154.Notch head test is used for measuring what?

Ans.
Notch head is used to meter flow of water in the
channel, by measuring the head of water over the v
notch crest. The v notch weir is especially good for
measuring a low flow rate, because the flow area
decreases rapidly as the head over the v notch gets
small.

155.Cantilever beam deflection

Ans.
These members would naturally deflect more as they
are only supported at one end. To calculate the
deflection of cantilever beam you can use the below
equation, where W is the force at the end, L is the
length of the cantilever beam, E = Young's Modulus
and I = Moment of Inertia.

156. Order of increasing thermal conductivity(AL, Stainless

steel, Cu and carbon steel)
Ans.
cu>al>carbon steel>stainless steel

157.Steel is designated by what content-alloy, carbon,

both.

43
 Ans.
Carbon steel, composed simply of iron and carbon,
accounts for 90% of steel production. Low alloy steel is
alloyed with other elements, usually molybdenum,
manganese, chromium, or nickel, in amounts of up to
10% by weight to improve the hardenability of thick
sections.

158. Gyroscopic motion-when ship’s rotor is turning

clockwise and the ship turns left what happens to the
ship’s stern and rear.
Ans.
Stern will raise and rear will sink

159. Engineering and true stress-strain curve are same

upto, which point?
Ans.
Yield point

160. Rubber has stress strain curve of what nature-Linear,

Nonlinear, first linear then non-linear.
Ans.
The stress-strain graph of rubber has an unusual shape.
When the load is first applied, the material is quite stiff
– as the stress is increased only a small strain is
observed and the gradient of the graph is high. ... A
large strain is observed for only small increases in
stress and the gradient of the graph decreases.so it is
linear in the starting and becomes nonlinear at the end.

161. Which is more dynamic or static friction

Ans.

44
 Static friction is more than dynamic friction.

162.Cylinder arrangement in planes is-radial perpendicular,

parallel.
Ans.
Cylinders in this engine are arranged in two in-line
banks, typically tilted 60–90 degrees apart from each
other and driving a common crankshaft. The vast
majority of V-engines are water-cooled. The V design
provides a higher power-to-weight ratio than an inline
engine, while still providing a small frontal area.

163. Find the frictional force of a body weighing 10 kg with

coefficient of friction 0.6take g=10m/s
Ans.
60N

164. How to reduce the whirling speed of shaft

Ans.
Vibrations in rotating machinery because many
problems such as fatigue of the rotating components,
excessive noise, or transmission of vibration to the
supporting structure. A major source of this vibration is
out-of-balance forces and this paper proposes that the
rotor response is reduced by suspending the machine
on nonlinear springs. In the field of vibration isolation,
nonlinear mounts have been proposed which have the
same static stiffness as an equivalent linear support,
i.e. load bearing capability, but at the same time offer a
low dynamic stiffness, i.e. a lower natural frequency.

165. Universal coupling is used to join.

45
 Ans.
Propeller shaft

166. What is feeler gauge used for?

Ans.
A feeler gauge is a tool used to measure gap widths.
Feeler gauges are mostly used in engineering to
measure the clearance between two parts.

167.Mass tied to a string is rotated in the vertical plane. At

which point is the possibility of string breaking the
max?
Ans.
Upper point of the circle

168. Dimension of coefficient of viscosity?

Ans.
N.s/m^3

169. Propeller of a ship is rotating in the clockwise

direction when seen from the stern (rear).If the ship
makes a left turn what would be the action due to the
gyroscopic precession.
Ans.
Rear will raise and stern will sink

170.Shear force and normal force on a 30deg plane for a

beam of 25mm*25mm acted upon by a tensile force of
20Kn.
Ans.
17.32kN, 10kN

46
 171. Max shear stress in the above case.
Ans.
27.712MPa

172. What is Engineering Design and say about the nature

of study?
Ans.
Engineering design is the method that engineers use
to identify and solve problems. It has been described
and mapped out in many ways, but all descriptions
include some common attributes Engineering design is
a process. This powerful approach to problem solving
is flexible enough to work in almost any situation.

173.What are the modeling softwares you have used?

Ans.
Few examples of modelling softwares are solid works,
AutoCAD, Autodesk Inventor.

174.Explain DFMA?
Ans.
DFMA stands for Design for Manufacture and
Assembly. DFMA is the combination of two
methodologies; Design for Manufacture, which means
the design for ease of manufacture of the parts that
will form a product, and Design for Assembly, which
means the design of the product for ease of assembly.

175.Have you any electronics based subjects?

Ans.

47
 Yes

176.When you are given a product, say mobile phone, how

will you approach i.e., start your design?
Ans.
First of all design of the basic electronic components.
The motherboard, PCB etc. then the basic dimensions
of the body and screen. The placement of the camera,
charging port and other such ports.

177.Why chose engineering design

Ans.
The prime purpose of engineering design is to apply
scientific knowledge to the solution of technical
problems. While engineers provide a technical solution,
it is very important to understand that engineering
design implies a solution that is aesthetic as well.

178.What you know about PLM software?

Ans.
PLM stands for product lifecycle management. It
studies the data related to this whole lifecycle and to
integrate the related data. PLM software can manage
product-related data. It can also combine the data with
ERP, MES, CAD etc.

179.What is otto and braytton cycle?

Ans.
The Otto cycle is a description of what happens to a
mass of gas as it is subjected to changes of pressure,
temperature, volume, addition of heat, and removal of
heat. The mass of gas that is subjected to those

48
 changes is called the system. The system, in this case, is
defined to be the fluid (gas) within the cylinder.
The Brayton cycle is a thermodynamic cycle named
after George Brayton that describes the workings of a
constant-pressure heat engine. The original Brayton
engines used a piston compressor and piston
expander, but more modern gas turbine engines and
air breathing jet engines also follow the Brayton cycle.

180. Explain first law of thermodynamics.

Ans.
The first law of thermodynamics is a version of the law
of conservation of energy, adapted for thermodynamic
processes, distinguishing two kinds of transfer of
energy, as heat and as thermodynamic work, and
relating them to a function of a body's state, called
Internal energy.

181. What is reynold’s number?

Ans.
The Reynolds number is an important dimensionless
quantity in fluid mechanics used to help predict flow
patterns in different fluid flow situations.

182.Critical reynold’s number-value.

Ans.
2300

183. Bearings constraints & types of bearings.

Ans.
There are two types of bearings, contact and non-
contact. Contact-type bearings have mechanical

49
 contact between elements, and they include sliding,
rolling, and flexural bearings. Mechanical contact
means that stiff- ness normal to the direction of motion
can be very high, but wear or fatigue can limit their life.

184. Types of forming processes.

Ans.
• Forging.
• Extrusion.
• Rolling.
• Sheet metal working.
• Rotary swaging.
• Thread rolling.
• Explosive forming.
• Electromagnetic forming.

185. Different types of heat transfer modes.

Ans.
• Conduction
• Convection
• Radiation

186. Different types of gears.

Ans.
Parallel Axes / Spur Gear, Helical Gear, Gear Rack, And
Internal Gear.
Intersecting Axes / Miter Gear, Straight Bevel Gear,
Spiral Bevel Gear.
Nonparallel, Nonintersecting Axes / Screw Gear, Worm,
Worm Gear (Worm Wheel)

50
 187.Different types of bearings.
Ans.
The most commonly used bearings are Deep-Groove
Ball Bearings.
• Angular Contact Ball Bearings.
• Self-Aligning Ball Bearings
• Thrust Ball Bearings
• Spherical Roller Bearings
• Cylindrical Roller Bearings
• Tapered Roller Bearings
• Needle Roller Bearings

188. Different types of materials.

Ans.
Materials can be classified into four main groups:
metals, polymers, ceramics, and composites. Metals
are materials on the left side of the periodic table of
chemistry and include ferrous metals that have iron
inside them (including steel) and nonferrous metals
that don't

189. How bearing balls are manufactured?

Ans.
The manufacturing process for ball bearings can be
broken down to four components: the outer race,
inner race, rolling balls and cage formation. Both the
inner and outer races are made using a similar process.
Starting with steel tubing, machine-cutting tools cut
the tubing slightly larger than the race shape.

190. Efficiency of Otto cycle. Draw Otto and diesel cycle.

Ans.

51
 In order to express the efficiency of the Otto cycle, we
need to evaluate the work performed by the gas
during one cycle and the heat, which the gas received
during this cycle. Efficiency is the proportion of the
work and the supplied heat.

191. What is BTU AND NTU?

Ans.
British thermal unit, National thermal unit

192.What is car differential? How does it work?

Ans.
A differential is a system that transmits an engine's
torque to the wheels. The differential takes the power
from the engine and splits it, allowing the wheels to
spin at different speeds. Turn it around a corner and
you will have no issues, as each wheel is able to turn
independently from the other.

193. Difference between commands in 8085

microprocessor (eg: - mov and mvi .etc)
Ans.
MVI instruction copies data between two registers,
whereas MOV instruction transfers an immediate data
into a register. transfers an immediate data into a
register. Both MOV and MVI instructions copy data
between two registers.

194. Architecture of 8085,8086 Microprocessor and PIC

microcontroller
Ans.
The architecture of 8085 microprocessor mainly

52
 includes the timing & control unit, Arithmetic and logic
unit, decoder, instruction register; interrupt control, a
register array, serial input/output control. The most
important part of the microprocessor is the central
processing unit.
8086 Microprocessor is an enhanced version of
8085Microprocessor that was designed by Intel in
1976. A 16-bit Microprocessor having 20 address lines
and16 data lines provides up to 1MB storage. It consists
of powerful instruction set, which provides operations
like multiplication and division easily.
PIC microcontroller architecture consists of memory
organization (ram, rom, and stack), CPU, timers,
counter, ADC, DAC, serial communication, CCP module
and I/O ports.

195. Clock frequency and time calculation

Ans.
Frequency = 1 / clock period. clock period = 1 /
frequency. For example, if a CPU operates at 100 Hz, its
"clock cycle" is 0.01 second = 10 ms; if it operates at 100
MHz, its clock cycle is 0.000 000 01 second = 10 ns.

196. Instruction length of 8085,8086,PIc(no. of bits)

Ans.
• 8085: 8 bit data bus
• 8086: 1-6 bytes

197.Pointers , Structures , Data types

Ans.
Pointer is a user defined data type, which creates

53
 special types of variables, which can hold the address
of primitive data type like char, int, float, double or
user defined data type like function, pointer, etc. or
derived data type like an array, structure, union,
enum.

198. OOPS concept in c++

Ans.
• Abstraction
• Encapsulation
• Modularity
• Inheritance
• Polymorphism

199. Data structures – stacks, queues

Ans.
• Stack: first in last out
• Queues: first in last out

200. Sorting algorithms comparisons

Ans.
Comparison Based Soring techniques are bubble sort,
selection sort, insertion sort, Merge sort, quicksort,
heap sort etc. These techniques are considered as
comparison based sort because in these techniques
the values are compared, and placed into sorted
position in different phases.

201.Networks – layers & functionalities

Ans.
Routers and gateways operate in the network layer.

54
 Network Layer provides mechanism for routing the
packets to final destination. Connection services are
provided including network layer flow control, network
layer error control and packet sequence control.

202. RDBMS—normal forms

Ans.
Relational Database Management System

203. Why embedded systems are used and example

Ans.
Examples of embedded systems are MP3 players,
mobile phones, video game consoles, digital cameras,
DVD players, and GPS. Household appliances, such as
microwave ovens, washing machines and dishwashers,
include embedded systems to provide flexibility and
efficiency.

204. What is DMA

Ans.
Direct memory access (DMA) is a feature of computer
systems that allows certain hardware subsystems to
access main system memory (random-access memory),
independent of the central processing unit (CPU).

205. What are the types of memories

Computer memory is of two basic type – Primary
memory(RAM and ROM) and Secondary memory(hard
drive,CD,etc.). Random Access Memory (RAM) is
primary-volatile memory and Read Only Memory
(ROM) is primary-non-volatile memory.

55
 206. Types of external memory
• External Hard Drives.
• Flash Drives.
• Memory Cards.

207. CD is better or USB is better

A USB is a solid state storage technology,and is
expensive as compared to CDs or any disc and has a
very long life (in terms of durability) as compared to
CD. ... A USB is a solid state storage technology,and is
expensive as compared to CDs or any disc and has a
very long life (in terms of durability) as compared to
CD.

208. Where multiplexers are used

A Multiplexer is used in numerous applications like,
where multiple data can be transmitted using a single
line. Communication System – A Multiplexer is used in
communication systems, which has a transmission
system and also a communication network.

209. Given a circuit with Resistor ratings (Resistance and

Power) find which of these resistors are more likely to
be damaged first.
The one with highest power rating

210.Manufacturing Process
Manufacturing engineering or manufacturing
process are the steps through which raw materials are
transformed into a final product. The manufacturing

56
 process begins with the product design, and materials
specification from which the product is made.

211. Lathe Project with diagram and specification

212. Welding
Welding is a fabrication or sculptural process that joins
materials, usually metals or thermoplastics, by using
high heat to melt the parts together and allowing them
to cool causing fusion. Welding is distinct from lower
temperature metal-joining techniques such
as brazing and soldering, which do not melt the base
metal.

213.Difference between orifice & diffuser

An orifice is any opening, mouth, hole or vent, as in a
pipe, a plate, or a body. Body orifice, any opening in the
body of a human or animal. Orifice plate, a restriction
used to measure flow or to control pressure or flow,
sometimes given specialized names: Calibrated orifice,
used to control pressure or flow. Diffuser may refer to:
Aerodynamics. Diffuser (automotive), a shaped section
of a car's underbody, which improves the car's
aerodynamic properties.

57
 214.Parallel & Counter flow heat exchangers
A counter-flow heat exchanger is one in which the
direction of the flow of one of the working fluids is
opposite to the direction to the flow of the other
fluid. In a parallel flow exchanger, both fluids in the
heat exchanger flow in the same direction.

215.Why do you like Manufacturing?

Yes because that is the process through which every
final product is obtained. Hence Manufacturing is
interesting.

216.What are the tools for planning?

 The Affinity Diagram.
 The Tree Diagram.
 The Interrelationship Diagram.
 The Matrix Diagram.
 Prioritization Matrices.
 The Process Decision Program Chart (PDPC)
 The Activity Network Diagram.

217. Castings
Casting is a manufacturing process in which a liquid
material is usually poured into a mold, which contains a
hollow cavity of the desired shape, and then allowed to
solidify. The solidified part is also known as a casting,
which is ejected or broken out of the mold to complete
the process.

218.Process involved in mould making

Molding or moulding (see spelling differences) is

58
 the process of manufacturing by shaping liquid or
pliable raw material using a rigid frame called a mold or
matrix. This itself may have been made using a pattern
or model of the final object.

219.Difference between Casting and Forming

Metal forming and metal casting are two classes of
techniques manufacturers use to shape metal.
Although casting is sometimes classified as a type
of forming, forming more properly describes other
approaches, like forging, which is very different from
casting molten metal.

220. Steps involved in Manufacturing

The steps include research, design and development,
logistics, production, sales and distribution, and
services.

221. What is ABS? Is the efficiency more than normal brakes.

ABS stands for antilock braking system. It is more
efficient than normal brakes.

222. What is Skidding? Reasons for Skidding

Clutch – sudden engagement of the clutch when on a
slippery surface. Combinations – skids are most often
caused by excessive speed, coupled with too sharp a
turn for the vehicle or braking when turning, or
"normal" speed coupled with ice or snow or gravel
on the road, etc.

223. How can we prevent Skidding

Choose the speed according to the weather

59
 conditions.
o You need to stay extremely attentive while
moving on wet or icy road and keep your both
hands on the driving wheel.
o Before turning or rounding a bend decrease
the speed -- it will help you stay in control of
the moving vehicle in the curve.

224. What is Centrifugal force? Formula

In Newtonian mechanics, the centrifugal force is an
inertial force (also called a " fictitious" or
"pseudo" force) that appears to act on all objects when
viewed in a rotating frame of reference. It is directed
away from an axis passing through the coordinate
system's origin and parallel to the axis of rotation.

225. What are the different type of threads in fasteners?

What are commonly used?
External threads are on bolts or screws.
Internal threads are on nuts. There are many forms of
threads but two types are in common use on fasteners.
Machine Screw Threads - used on bolts, setscrews,
machine screws and designed to mate with preformed
threads in nuts or tapped holes.

226. Where is Square thread used?

The square thread form is a common
screw thread form, used in high load applications such
as leadscrews and jackscrews. It gets its name from
the square cross-section of the thread. It is the lowest
friction and most efficient thread form, but it is difficult
to fabricate.

60
 227. What is positive displacement machine?
A positive displacement pump makes a fluid move by
trapping a fixed amount and forcing (displacing) that
trapped volume into the discharge pipe. Some positive
displacement pumps use an expanding cavity on the
suction side and a decreasing cavity on the discharge
side.

228. Define the term Turbomachine

Elaborating, a turbomachine is a power or head
generating machine which employs the dynamic action
of a rotating element, the rotor; the action of the rotor
changes the energy level of the continuously flowing
fluid through the machine. Turbines, compressors and
fans are all members of this family of machines.

229. Draw the sketch of a pump

257. Types of manufacturing process

61
 Most manufacturing environments fit into one of five
general categories. Repetitive, Discrete, Job
Shop, Process (batch), and Process (continuous).
Most companies use more than one of these
environments to get a single product out the door.

258.Why can’t we use 8 cylinders in a engine by increasing

the size instead of 16 ?
We cant have variable firing order and enough power
wont be produced.

259.Difference between Soldering & Welding?

The main difference between welding and soldering is
melting. In soldering, metal fabricators heat the metal
to be bonded but never melt them. Welding requires
about 6,500 degrees Fahrenheit,
while soldering requires about 840 degrees
Fahrenheit. Work pieces and the metal base are
heated and melted in welding.

260. Joining process other than welding and riveting?

Using nut and bolt

261. Surface finish measures

Surface finish measurement, sometimes called surface
texture measurement, is the characterizing of
a surface's quality or conformance to expectations
(for example, to an engineering specification)
through measurement of its variations in local height
over a given distance.

262. Powder Metallurgy

62
 The powder-metallurgy (PM) process, depicted in the
diagram below, involves mixing elemental or
alloy powders, compacting the mixture in a die, and
then sintering, or heating, the resultant shapes in an
atmosphere-controlled furnace to metallurgically bond
the particles.

263. Jet Engine

A jet engine is a type of reaction engine discharging a
fast-moving jet that generates thrust by jet
propulsion. While this broad definition can
include rocket, water jet, and hybrid propulsion, the
term jet engine typically refers to an airbreathing jet
engine such as a turbojet, turbofan, ramjet, or pulse
jet. In general, jet engines are combustion engines.

263. Shocks
A shock absorber or damper is a mechanical
or hydraulic device designed to absorb
and damp shock impulses. It does this by converting
the kinetic energy of the shock into another form of
energy (typically heat) which is then dissipated. Most
shock absorbers are a form of dashpot (a damper
which resists motion via viscous friction).

264. Flow separation

Flow separation or boundary layer separation is the
detachment of a boundary layer from a surface into a
wake. Separation occurs in flow that is slowing down,
with pressure increasing, after passing the thickest
part of a streamline body or passing through a
widening passage, for example.

63
 265. Alloys
An alloy is a combination of metals or metals combined
with one or more other elements. For example,
combining the metallic elements gold and copper.

265. Manufacturing Process

Manufacturing engineering or manufacturing
process are the steps through which raw materials are
transformed into a final product. The manufacturing
process begins with the product design, and materials
specification from which the product is made.

266. Working of compressors

The basic working principle of an air compressor is to
compress atmospheric air, which is then used as per
the requirements. In simpler terms, free or
atmospheric air is compressed after reducing its
volume and at the same time, increasing its pressure.

267. Different type of studs

With respect to shape, stud bolts a.k.a. studs are
categorized into 3 basic types: "Fully
Threaded Stud Bolts", "Tap End Stud Bolts", and
"Double End Stud Bolts". Each of
these studs have different application.

268. Factor of safety

In engineering, a factor of safety (FoS), also known as
(and used interchangeably with) safety factor (SF),
expresses how much stronger a system is than it
needs to be for an intended load. Safety factors are

64
 often calculated using detailed analysis because
comprehensive testing is impractical on many projects,
such as bridges and buildings, but the structure's
ability to carry a load must be determined to a
reasonable accuracy.

269. Engine design factors

The factors are:
 Number of cylinders
 stroke-to-bore (S/B) ratio
 Valve flow area related to
number of valves and valve
size
 Valve overlap height
 The 'K-factor' used to measure
the proportion of air available
for combustion.

270.Difference process in manufacturing

Machining, joining, casting, powder metallurgy,
forming, forging etc.

271. Difference between casting & forging

Casting is the process where metal is heated until
molten. While in the molten or liquid state it is poured
into a mold or vessel to create a desired
shape. Forging is the application of thermal and
mechanical energy to steel billets or ingots to cause
the material to change shape while in a solid state.

272. How do you do casting process

Make your patter, cope, drag and tools ready. Pour the

65
 molten metal and let it cool for the calculated time.
Then remove the casted model and give finishing’s.

273. Green sand making

o Digging Clay. Buy or dig some clay.

o Find Some Sand. Buy or dig sand.

o Make Clay Into Fine. Make clay into fine and clean
the sand if it has any contaminant.

o Formula. My formula of green sand is 70% of sand

and 30 % of clay.
o Finally mix sand with clay. During the process,
spray some water.
274. Properties of Green sand
Flowability increases as the clay and water content
increases. The molding sand that contains moisture is
termed as green sand. The strength of
the sand in green or moist state is termed
as green strength. The green sand particles have the
ability to cling to each other to impart sufficient
strength to the mold.

275.Lathe parts and explain

66
 276.Viscosity & it's unit
Resistance offered by fluid against motion is called
viscosity. The SI unit of viscosity is the Pascal second
(Pa·s) or kg·m−1·s−1. The SI unit of
kinematic viscosity is square meter per second or m2/s.
CGS Unit of Viscosity: The cgs unit of viscosity is poise
(P) and this name has been used in honor of a French
physiologist Jean Léonard Marie Poiseuille.

277. Welding parameters, Voltage, Current

The four important parameters are
the welding current, wire electrode extension, welding
voltage and arc travel speed. These parameters will
affect the weld characteristics largely. Because these
factors can be varied over a large range, they are
considered the primary adjustments in
any welding operation.

278. Difference between TIG and MIG

TIG and MIG welding are arc welding processes in
which the molten weld pool is protected from the
atmosphere by a shroud of inert gas around the arc.
How they differ.
67
 TIG welding uses non-consumable tungsten electrode
to produce arc between the electrode and the work.
As the electrode is non-consumable, maintenance of
steady arc is easy. Control over molten weld pool is
also superior. If the joint requires addition of filler
material to fill the gap, it is added separately. In this
case both hands of operator are busy.
MIG welding uses the filler metal wire itself to produce
arc and in turn melts itself to add to weld pool. There is
no need of additional filler wire in this case. Welding
current in this case is decided by wire speed and
power supply volt-ampere characteristic. Control over
arc and metal transfer in MIG welding is inferior to TIG
welding. Productivity of MIG welding is significantly
higher. MIG welding torch is bulkier compared to TIG
welding torch.
TIG welding is preferred where high quality of weld
(radiography) is essential

279. Types of boilers

 Haycock and wagon top boilers.

 Cylindrical fire-tube boiler.
 Multi-tube boilers.
 Solid fuel firing.
 Firetube boiler.
 Superheater.
 Water tube boiler.
 Supercritical steam generator.

280. Latent heat, Sensible heat

Latent heat is energy released or absorbed, by a body

68
 or a thermodynamic system, during a constant-
temperature process — usually a first-order phase
transition. 
Sensible heat is heat exchanged by a body or
thermodynamic system in which the exchange of heat
changes the temperature of the body or system, and
some macroscopic variables of the body or system,
but leaves unchanged certain other macroscopic
variables of the body or system, such as volume or
pressure.

281. Different kinds of turbo machinery

 Axial compressor.
 Axial fan.
 Centrifugal compressor.
 Centrifugal fan.
 Centrifugal pump.
 Centrifugal type supercharger.
 Exoskeletal engine.
 Francis turbine.

282.What are the factors for a pump?

 Capacity:
 Power:
 Cost.
 Maintenance:
 Efficiency:
 Depreciation:
 Cost of labour:
 Number of pumping:

283. Bernoulli’s theorem

69
 The total mechanical energy of the flowing fluid,
comprising the energy associated with fluid pressure,
the gravitational potential energy of elevation, and the
kinetic energy of fluid motion, remains constant.

284. What are factors in design of components

Good design engineers must consider so
many factors when designing a part or
component. Design for assembly, cost, logistics,
manufacturability, reliability, and other qualities all
require forethought and creativity.

285. Where are pumps used?

They are used often in oil refineries and power plants.
They are also the pump of choice for municipal water
applications. They are used to move the general water
supply from the pressure main in cases where a little
or no suction lift is required.

286. Iron carbon diagram

70
 287. Heat treatment process
There are five basic heat treating processes:
hardening, case hardening, annealing, normalizing,
and tempering. Although each of
these processes bring about different results in metal,
all of them involve three basic steps: heating, soaking,
and cooling. Heating is the first step in a heat-treating
process.

288. Fluid : Viscosity, Surface Tension, Laminar/Turbulent

flows,
The viscosity of a fluid is a measure of its resistance to

71
 deformation at a given rate.
Surface tension is the tendency of fluid surfaces to
shrink into the minimum surface area possible.
Laminar flow is a flow regime characterized by high
momentum diffusion and low momentum convection.
Turbulent flow is a type of fluid (gas or liquid) flow in
which the fluid undergoes irregular fluctuations, or
mixing, in contrast to laminar flow, in which the fluid
moves in smooth paths or layers. 

289. Reynold's number and its significance

The Reynolds number is defined as the product of
density times velocity times length divided by the
viscosity coefficient. This is proportional to the ratio of
inertial forces and viscous forces (forces resistant to
change and heavy and gluey forces) in a fluid flow.

290. What are the different machining processes used for

making an automobile?
 CNC Milling.
 Parts manufactured through milling.
 Rack and pinion systems machining.
 Turning.
 Automotive parts made through turning.
 Drilling.

291. Explain Ranking cycle

 Process 1–2: The working fluid is pumped from
low to high pressure. As the fluid is a liquid at
this stage, the pump requires little input
energy.
72
 In other words Process 1-2 is [Isentropic
compression in pump]
 Process 2–3: The high-pressure liquid enters a
boiler, where it is heated at constant pressure
by an external heat source to become a dry
saturated vapour. The input energy required
can be easily calculated graphically, using
an enthalpy–entropy chart (h–s chart,
or Mollier diagram), or numerically,
using steam tables.
In other words Process 2-3 is [Constant pressure
heat addition in boiler]
 Process 3–4: The dry saturated vapour
expands through a turbine, generating power.
This decreases the temperature and pressure
of the vapour, and some condensation may
occur. The output in this process can be easily
calculated using the chart or tables noted
above.
In other words Process 3-4 is [Isentropic
expansion in turbine]
 Process 4–1: The wet vapour then enters
a condenser, where it is condensed at a
constant pressure to become a saturated
liquid.

292. Difference between turbines and compressor

 Turbine delivers work, while
compresor requires work.
 Turbine extract energy by
decreasing the pressure, while

73
 compressor increase fluid
pressure.
 This because turbines deliver
works by decreasing total pressure
to certain static pressure, without
its dynamic velocity. While
compressor requires energy to
achieved total pressure at the
outlet.
 Reheat for turbine increases
effiicency by deliver more works.
In compressor usually use
intercooler, not preheater to
increase efficiency.

293. Relate Rankine cycle and turbines

Rankine cycle with reheat In this variation,
two turbines work in series. The first accepts vapor
from the boiler at high pressure. After the vapor has
passed through the first turbine, it re-enters the boiler
and is reheated before passing through a second,
lower-pressure, turbine.

294. Heat exchangers and different types. Explain with

graph.
A heat exchanger is a system used to
transfer heat between two or more fluids. Heat
exchangers are used in both cooling
and heating processes.
 Parallel-flow and counter-flow heat
exchanger.
 Finned and Unfinned tubular heat exchanger.

74
  U-tube, single pass straight and two pass
straight heat exchanger.
 Plate-and-frame heat exchanger.
 Pate-fin heat exchanger.
 Microchannel heat exchanger.

295. Basic machine elements

Machine Elements was traditionally seen as basic
mechanical parts, mostly used as the building blocks in
the design of machines. Most of the classical elements
such as shafts, bearings, gears, couplings, fasteners,
springs, seals, belts, clutches, brakes and chains are
standardized to common sizes.

296. Application of turbines in automobiles.

Gas turbine engines have numerous advantages over
the piston engines that drive most of our cars. Their
high power to weight ratio makes them better suited
for large jobs, and they operate well at high altitudes.
They are not dependent on petroleum fuels, but can
run on natural gas, kerosene, jet fuel and biofuels.

297. Bending moment and shear force diagram for a

cantilever beam with simple load

75
 298. What is the use of a production engineer in
production department?
Production engineers work in the sphere
of manufacturing, overseeing the production of goods
in many industries at factories or plants. Their main job
is to ensure that all products are manufactured with
utmost efficiency and quality, according to planned
protocols using the appropriate technology.

299. Difference between Jigs & fixtures

The key difference between Jigs and Fixtures is that
a jig is a type of tool used to control the location or
motion of another tool. On the other hand, a fixture
is a support or work holding device used to hold work
in place.

300. Use of wings in race cars

Race car wings or aerofoils operate on same principle
that allows an airplane to rise off the ground by
creating lift from its wings is used in reverse to apply
force that presses the race car against the surface of
76
 the track.

301. Casting
Casting is a manufacturing process in which a liquid
material is usually poured into a mold, which contains
a hollow cavity of the desired shape, and then allowed
to solidify. The solidified part is also known as
a casting, which is ejected or broken out of the mold
to complete the process.

302. Brake thermal efficiency

Brake Thermal Efficiency is defined as break power of a
heat engine as a function of the thermal input from
the fuel. It is used to evaluate how well an engine
converts the heat from a fuel to mechanical energy.

303. Speed, Time and Distance

To find the speed, distance is over time in the triangle,
so speed is distance divided by time. To
find distance, speed is beside time,
so distance is speed multiplied by time.
304. Turbines and Flow meters
A turbine flow meter is a volume sensing device. As
liquid or gas passes through the turbine housing, it
causes the freely suspended turbine blades to rotate.
The velocity of the turbine rotor is directly
proportional to the velocity of the fluid passing
through the flow meter.

305. What are springs

A spring is an elastic object that
stores mechanical energy. Springs are typically made

77
 of spring steel.

306. Stiffness of a spring

The stiffness, k, of a body is a measure of the
resistance offered by an elastic body to deformation.
every object in this universe has some
stiffness.generally for spring the spring stiffness is the
force required to cause unit deflection.

307. Refrigeration cycle

Basic Refrigerator principle is reverse carnot cycle.
Essentially, heat is taken from a body at lower
temperature, say the food you want to store in the
refrigerated chamber. receives additional energy and
rejects heat to higher temperature body,say
surrounding atmosphere.

308. Difference between 2 stroke and 4 stroke? Which is

efficient?
In a 2-stroke engine, the entire combustion cycle is
completed with just one piston stroke: a compression
stroke followed by the explosion of the compressed
fuel. During the return stroke, the exhaust is let out
and a fresh fuel mixture enters the cylinder. The spark
plugs fire once every single revolution, and power is
produced once every 2-strokes of the piston. Two-
stroke engines also require the oil to be pre-mixed in
with the fuel.
In a 4-stroke engine, the piston completes 2-strokes
during each revolution: one compression stroke and
one exhaust stroke, each being followed by a return
stroke. The spark plugs fire only once every other

78
 revolution, and power is produced every 4-strokes of
the piston. These engines also do not require pre-
mixing of fuel and oil, as they have a separate
compartment for the oil.
As far as efficiency goes, the 4-stroke certainly wins.
This is due to the fact that fuel is consumed once every
4 strokes.

309. Does diesel two stroke engine exist?

yes

310. What are the uses of springs?

These springs can be used in the following industries:
manufacturing, transportation, construction, materials
handling, agricultural, aeronautical, and many more.
Each function of a big or small machine is determined
by the compression spring. These springs work by
absorbing potential energy as they expand.

311. What is turbocharger?

A turbocharger, colloquially known as a turbo, is a
turbine-driven, forced induction device that increases
an internal combustion engine's efficiency and power
output by forcing extra compressed air into the
combustion chamber.

312. Concepts of mechanical advantage

The ratio of the force produced by a machine to the
force applied to it, used in assessing the performance
of a machine.

79
 313. Difference between Quality assurance and Quality
control
“Quality Control” is a somewhat reactive
approach based heavily on inspection to find
defects before the product is ready for release or
shipment or at the end of selected stages in the
development or manufacturing process.
“Quality Assurance” is a much broader and
more proactive approach that attempts to go
upstream in the process to eliminate defects at
the source. The goal of an effective Quality
Assurance effort is to design processes and
systems that are inherently reliable in producing
high-quality products.
“Quality Assurance” takes a holistic
approach to identifying and trying to influence
all the factors that might have some impact on
the quality of products including the role of
people in producing those products.
An effective Quality Assurance effort can significantly
improve the level of quality over a Quality Control
approach because a Quality Control approach is based
heavily on inspection and sampling to find defects and
it would be very expensive and impractical to do 100%
sampling. An effective Quality Assurance effort can
also reduce costs by reducing the need for inspectors
that are required to find defects after the product is
built.

314. Is quality control has only to do with sampling or what

else is going on?
Quality control (QC) is a process by which entities
review the quality of all factors involved in

80
 production. ISO 9000 defines quality control as "A part
of quality management focused on fulfilling quality
requirements".

315. Why does sampling frequency vary?

In signal processing, sampling is the reduction of
a continuous-time signal to a discrete-time signal. A
common example is the conversion of a sound wave (a
continuous signal) to a sequence of samples (a
discrete-time signal).
A sample is a value or set of values at a point in time
and/or space. A sampler is a subsystem or operation
that extracts samples from a continuous signal. A
theoretical ideal sampler produces samples equivalent
to the instantaneous value of the continuous signal at
the desired points.

316. Explain about your project in layman's terms

I haven’t started anything yet.

317. Pressure die casting

Pressure die casting is a quick, reliable and cost-
effective manufacturing process for production of high
volume, metal components that are net-shaped have
tight tolerances. Basically, the pressure die
casting process consists of injecting under
high pressure a molten metal alloy into a steel mold (or
tool).

318. Material specifications

A specification often refers to a set of documented
requirements to be satisfied by a material, design,

81
 product, or service.
A requirement specification is a documented
requirement, or set of documented requirements, to
be satisfied by a given material, design, product,
service, etc.

319. Material Science - TTT diagram, Heat treatment process

82
 There are five basic heat treating processes: hardening, case
hardening, annealing, normalizing, and tempering. Although each
of these processes bring about different results in metal, all of
them involve three basic steps: heating, soaking, and
cooling. Heating is the first step in a heat-treating process.

320. Strength of materials

In mechanics of materials, the strength of a material is
its ability to withstand an applied load without failure
or plastic deformation. The field of strength of
materials deals with forces and deformations that
result from their acting on a material.

321. Solid mechanics - SFD, BMD

Shear Forces occurs when two parallel forces act out
of alignment with each other. Bending Moments are
rotational forces within the beam that cause bending.
At any point within a beam, the Bending Moment is
the sum of: each external force multiplied by the
distance that is perpendicular to the direction of
the force.

322. IC Engines
83
 An internal combustion engine (ICE) is a heat engine in
which the combustion of a fuel occurs with an oxidizer
(usually air) in a combustion chamber that is an
integral part of the working fluid flow circuit.

323. Concepts of mechanical advantage

The advantage gained by the use of a mechanism in
transmitting force specifically : the ratio of the force
that performs the useful work of a machine to the
force that is applied to the machine.

324. Refrigeration cycle schematic [mention state of

refrigerant, temperature and pressure at each stage]

325. Difference between refrigeration and air-conditioning

Refrigeration is a processes that take thermal
energy away from a place and gives off that energy to
a place with a higher temperature. Naturally, thermal
energy flows from a place with a higher temperature
to a place with a lower temperature. Therefore,
refrigeration runs against the natural heat flow and so
it requires external work.

84
 Air conditioners work in the same way as
refrigerators. The primary difference is that air
conditioners are not only concerned with maintaining
the temperature of the air, they also help to regulate
humidity and filter the air.

326. Comfort temperature and humidity [value range]

Humans generally
feel comfortable between temperatures of 22 °C to 27
°C and a relative humidity of 40% to 60%.

327. Purpose of differential.

To maneuver the automobile sometimes we need
maintain different rpm of the two rear wheels of an
automobile so differential helps in achieving the task.

328. Difference between quality assurance and quality

control.

329. What are the different types of threads?

There are six different types of threads in general
o UN/UNF

85
 o NPT/NPTF
o BSPP (BSP, parallel)
o BSPT  (BSP, tapered)
o Metric parallel
o Metric tapered.

330. What are the different types of pumps?

There are three basic types of pumps
o positive displacement
o centrifugal
o Axial-flow pumps.

331. What is difference between shaping and planing?

86
 332. What type of thread is used in lathe?

87
 333. Flow chart of thermal power plant?

334. What is a generator, difference between generator and

motor? Cooling system of generator?
Generators are machines that produce electric
energy in the form of voltage and current. They
produce electricity based on the principle of
electromagnetic induction. There are two
fundamental types of generators known as AC
(alternating current) and DC (direct
current) generators
A generator converts mechanical energy into
electrical energy, while a motor does the opposite - it
converts electrical energy into mechanical energy.
Both devices work because of electromagnetic
induction, which is when a voltage is induced by a
changing magnetic field.

88
 In air-cooling systems, the engine takes cool air
from the atmosphere and blows it internally across the
different parts of the generator set. This keeps
the generator from overheating.

335. Types of welding?

336. Purpose of gear box?

The main purpose of a gear box is to multiply the
torque available in the driving wheels so that a wide
range of torque is available in the same. The speed of
the engine crankshaft is very high typically varies from
1000 to 7000 rpm and we need too reduce it to the
range of 0-1800 rpm, the rpm of the wheels.

337. Why is there a compartment in tanker Lorries inside the

container?
Other than that, different compartments help to
deliver to a wider variety of consumers. For example -
A may require lesser quantity of product than the full
capacity of the container, and similarly with B and C

89
 and so on. Thus the container can carry the optimum
load and deliver the same to A, B

338. Which one has higher tensile strength? Electrode or

the material to be welded?
Electrode has higher tensile strength

339. What is the difference between shaping and planing?

340. What are the operations in Lathe machine?

90
 341. Where shaping and planing used?
o Applications of Shaper Machine:
o To generate straight and flat surfaces.
o Smooth rough surfaces.
o Make internal splines.
o Make gear teeth.
o To make dovetail slides.
o Make key ways in pullies or gears.
o Machining of die, punches, straight and curved slots.

91
 o Usage of planing machines
o The most common applications of planers and
shapers are linear-toolpath ones, such as: Generating
accurate flat surfaces. (While not as precise as
grinding, a planer can remove a tremendous amount
of material in one pass with high accuracy.) Cutting
slots (such as keyways).

342. Use of inert gas in TIG welding?

Inert gases like Argon provide as an inert gas shield in
some welding practices, like TIG welding. A
shielding gas such as argon is utilized in TIG welding to
lower the risk of exposure of the molten weld pool to
oxygen, nitrogen and hydrogen that can be present in
the atmosphere.

343. Carnot cycle, Otto cycle. Applications of the same

Carnot Cycle
Definition of Carnot cycle. : an ideal reversible
closed thermodynamic cycle in which the working
substance goes through the four successive
operations of isothermal expansion to a desired point,
adiabatic expansion to a desired point, isothermal
compression, and adiabatic compression back to its
initial state.
Application - Carnot heat engine, Refrigeration.
Otto Cycle
The Otto cycle is a description of what happens
to a mass of gas as it is subjected to changes of
pressure, temperature, volume, addition of heat, and
removal of heat. The mass of gas that is subjected to
those changes is called the system. The system, in this
case, is defined to be the fluid (gas) within the
cylinder.
92
 Applications - Automobiles, Lawn mowers.

344. Difference between diesel and Petrol engine.

345. What is Entropy, Enthalpy

Entropy
The entropy of an object is a measure of the
amount of energy which is unavailable to do
work. Entropy is also a measure of the number of
possible arrangements the atoms in a system can
have. In this sense, entropy is a measure of uncertainty
or randomness.
Enthalpy
Enthalpy a property of a thermodynamic system,
is equal to the system's internal energy plus the
product of its pressure and volume. In a system
enclosed so as to prevent mass transfer, for processes
93
 at constant pressure, the heat absorbed or released
equals the change in enthalpy.

346. Difference between bevel gear, spur gear

347. Load sharing in automobiles

Load sharing is a term used by many to describe a
system where multiple drive and motor sets are
coupled and used to run one mechanical load.

348. Use of starters in motors

Starters are used to protect DC motors from damage
that can be caused by very high current and torque
during startup. They do this by providing external

94
 resistance to the motor, which is connected in series
to the motor's armature winding and restricts the
current to an acceptable level.

349. Use of ignition coil

Ignition coils are known as compact electrical
transformers. Their purpose is to take the low 12-volt
current normally found in car batteries and convert it
into a much higher voltage which is needed to ignite
the fuel and start the engine. Each spark plug in a car
has its own ignition coil.

350. Power system management in India and it’s

importance
India is the world's third largest producer and
third largest consumer of
electricity. The national electric grid in India has an
installed capacity of 368.79 GW as of India began using
grid management on a regional basis in the 1960s.
the single most important cause for pollution of
surface and groundwater in India.

351. Role of electrical in automobile industry.

High-tech systems started appearing in cars in the
1980s, and today, auto electronic systems and engine
computers do everything from regulating
fuel to diagnosing problems. Most of today's cars have
between 30 and 80 separate electronic controllers.
Some of these devices have an obvious effect on
safety. Adaptive cruise control, which slows the
vehicle down if another car is detected in front of it,
or lane assist systems, which warn a driver if he or she
is leaving the lane without signaling, are just two
examples.

95
 In-car computers give drivers a way to control multiple
devices from inside the car. A sensor with a simple job,
like detecting the outdoor temperature so you can see
it on a display, automotive sensors also perform critical
tasks that directly affect safety on the road like a
sensor might measure the angle of the car to keep it in
the right gear while accelerating. Or, sensors might
sense slipping wheels in bad weather, signaling the car
to turn on electronic stability control.

352. What do you mean by non destructive testing?

Nondestructive testing (NDT) is a wide group of
analysis techniques used in science and technology
industry to evaluate the properties of a material,
component or system without causing damage.

353. How is quality of a product checked in a company?

Quality control involves testing of units and
determining if they are within the specifications for the
final product. The purpose of the testing is to
determine any needs for corrective actions in the
manufacturing process. Good quality control
helps companies meet consumer demands for
better products.

354. About in-plant training-manufacturing process and

quality testing
In manufacturing, quality control is a process that
ensures customers receive products free from defects
and meet their needs. When done the wrong way, it
can put consumers at risk.

355. Defects in casting

96
 356. Harmonics in a system.
A harmonic is a voltage or current at a multiple
of the fundamental frequency of the system,
produced by the action of non-linear loads such as
rectifiers, discharge lighting, or saturated magnetic
devices.

357. What are different modes of vibrations for a cantilever

beam?
Vibrations of Cantilever Beams: Measurements of
thin film properties are difficult when compared to
bulk materials. One method for finding the modulus of
elasticity of a thin film is from frequency analysis of
97
 a cantilever beam. A straight, horizontal cantilever
beam under a vertical load will deform into a curve.

358. Significance of mode shapes.

The natural frequencies and mode shapes are
arguably the single most important property of any
mechanical system. This is because, as we shall see,
the natural frequencies coincide (almost) with the
system's resonant frequencies.

359. Define damping ratio. Explain under damping, critical

damping, over damping.
Damping Ratio
The damping ratio is a dimensionless measure
describing how oscillations in a system decay after a
disturbance. Many systems exhibit oscillatory
behavior when they are disturbed from their position
of static equilibrium. A mass suspended from a spring,
for example, might, if pulled and released, bounce up
and down.

98
 Over Damped: The O airplane takes off very slowly
and hence has a very high value of Rise Time as
compared to other two systems. Rise time being
defined as time taken to reach the level of center of
the blue denoted by dotted line in the figure. Also due
to some navigational anomalies it never reaches its
destination and stays below the required height.
Critically Damped: The C plane is better than the
O and almost (asymptotically) reaches the target and
that too at a better speed and less time than O.
Under Damped: The U plane pilot is very
enthusiastic and in its excitement goes at very high
speed hence goes pass the target and that too in very
less time (Rise Time) as compared to other two
planes. Releasing his mistake it again comes back but
again enthusiasm kicks in and he again passes the
destination this time in opposite direction. This
process continues until a specific time until he is
settled. We call this time as the Settling Time and after
this time he finally reaches his destination.

99
 360. Solve a given beam problem in MOS.
 Combine the two applied forces into
one and find the line of action.
 Owing to the roller support reaction
RB will be vertical. Therefore the
resultant line (RL) must be extended
to intersect the vertical reaction of
support B. This point is the point of
concurrency for the resultant load, the
reaction at B and the reaction at A.
 From this point of concurrency, draw a
line through the support pin at A. This
gives the line of action of the reaction
at A.
 Use these three force directions and
the magnitude of RL to draw the force
diagram, from which RA and RB can
be found.
360. Application of damping in automobiles. Kind of
damping in automobile suspension.
Damper is a shock absorber that is used in
independent suspension system to absorb the
vibrational energy by resisting motion via viscous
friction. ... An automobile shock absorber contains
spring-loaded check valves and orifices to control the
flow of oil through an internal piston.

361. Heat transfer

Heat transfer is a discipline of thermal
engineering that concerns the generation, use,
conversion, and exchange of thermal energy between
physical systems. Heat transfer is classified into various

100
 mechanisms, such as thermal conduction, thermal
convection, thermal radiation, and transfer of energy
by phase changes.

362. Conduction, transfer coefficient

The heat transfer coefficient or film coefficient,
or film effectiveness, in thermodynamics and
in mechanics is the proportionality constant between
the heat flux and the thermodynamic driving force for
the flow of heat (i.e., the temperature difference, ΔT):
The overall heat transfer rate for combined
modes is usually expressed in terms of an overall
conductance or heat transfer coefficient, U. In that
case, the heat transfer rate is:

363. 140. Spring force, effective spring constant

Spring Force
The spring force is called a restoring force because
the force exerted by the spring is always in the opposite
direction to the displacement.
Effective spring constant

101
 364. Enterprise resource planning.

365. What are the steps for servicing a diesel engine

There are about five important steps for
servicing a diesel engine and they are
Monitor Your Coolant. Your diesel engine's
coolant is one of its most
important maintenance needs.

102
 Keep It Clean.
Fuel Filter Changes.
Effective Air Filters.
Appropriate Oil Changes.

366. What do you mean by 1 ton in AC`s.

1 ton represents the cooling capacity of the air
conditioner, which means it can melt 907 Kg’s of ice in
24 hours.

367. How marginal costing is used in manufacturing sectors,

what is the method/steps for using marginal costing
Marginal costing is the accounting system in which
variable costs are charged to cost units and
fixed costs of the period are written off in full against
the aggregate contribution. Marginal costing is also
the principal costing technique used in decision
making.
368. Critical stress at which material will start to flow
The material stats to flow at the yield stress.

369. Maximum degree of freedom in space.

o Maximum of 6 degrees of freedom is
possible in 3D space
o Maximum of 3 degrees of freedom is
possible in 2D space

370. Bearing which will take axial and radial loads.

Deep groove ball bearing.

371. Fluid is flowing through a frustum of cone. What is the

nature of graph of velocity Vs. c/s area. {flow = velocity
X c/s area}
Hyperbolic in nature
103
 372. Explain type of flow of fluid in a pipe having no change
in profile.
Laminar flow is
a  flow regime that
doesn’t change its
profile with respect to
time in a pipe

373. Which material can't be removed during alloying from

Fe alloys.
Arsenic (As)

374.Time dependent increase in length at steady temp. is

called?
Poisson’s equations

375.How does viscosity change with temp

104
 376.Direction of friction in bicycle tyres
Opposite to direction of cycle motion

377.Questions related to stress, strain, Ratios etc

378.Find reinforcement place for a cantilever beam loaded
at free end
The Fixed end.

379.Two force acting along the same line but in the

opposite directions are called
Equal and opposite concurrent forces

380. Formula for power in HP

1HP= 786 Watts

381. Gear ratio for helical gears one of 30 tooth and the
other 60 tooth
2:1

105
 382.A ball of weight 10N is dropped freely from rest at a
height of 4 mts. what is its total mechanical energy
after it has traveled 1 meter.
30N

383. Two bodies of same mass r traveling at a velocity of 2

m/sec in opposite direction. After collision one travelled
with 1.8 m/sec what about the other
2.2 m/sec (Conservation of momentum)

384. A chain of length 1 mt and mass 1 kg is placed on a

table. What length of the chain must be hanged freely
from the table so that is will drag the remaining chain
freely
It depends on the coefficient of friction of the table.

385. Main purpose of governor

It is used to set the maximum speed of the moving vehicle.

386. Belt drives are mainly used for

transmitting power in a cheap and cost-efficient manner.

387.The main purpose of bearings

It is used to bear the loads and act like a support for the rotating
machine elements.

388. Why Poisson’s ratio cannot be greater than 0.5?

It means that for the given material, volume will increase while
elongating which is not possible.

389. Draw Shear force diagram and bending moment

diagram for the given figure?

106
 No figure is provided.

390. Find the height ‘y’ a projectile with velocity ‘v’ at angle
‘a’ is sent. What are the parameters you will require to
find the hit on target with high probability?
2
y = V² x sin (a) / (2 * g)

391. Determine cost for an aluminum bin open at the top

with specified dimensions if aluminum costs 3000/Kg?

392.Find the equation for displacement for the vibration

problem?
The crank with small mass rotates at constant angular velocity,
causing the mass m to vibrate. It is of particular interest to
determine the influence of forcing amplitude and
frequency on the motion of the mass. We follow the same
approach to analyze each system: we set up, and solve
the equation of motion.

393. Compare a hollow and a solid shaft of given

dimensions for both maximum shear stress and twist?
Solid shaft is better

394. Derive the dimensions of Dynamic Viscosity?

Kg/m.s

395. BF & SF for the beam shown?

107
 396. Maximum angle at which the projectile to clear the
height h.
 h = V₀² x sin2(∅ ) / (2 * g)

397.Numerical based on double shear ?

There are two shafts one is hollow with inner and outer radii a
and√2 a and other is a solid shaft with radius c. Get the
relationship between c and a such the same the same
torque T and shear stress and twist does not increase
above the limit for the hollow shaft (hint : design for both
strength and rigidity)

398. Mesh the given 2D object - hint: apply finer mesh to

the areas of stress concentration

399. Why is bamboo used for making furniture?

They are Strong and grow very fast.

108
 400. Calculation of the cost of aluminum for a given inner
and outer diameter of a bin?
Idk

401.Problem on the torsion of a cylinder.

No problem is given

402. Projectile motion of an object? and finding the height

where it impacts the wall?
h = V₀² x sin2(∅ ) / (2 * g)

403. A problem on vibration analysis of a sphere connected

to a spring?
Recall that a system is conservative if energy is conserved, i.e.
potential energy + kinetic energy = constant during
motion. Free vibration means that no time varying external
forces act on the system.

404. Stress vs strain graph for brittle and ductile material

109
 405. Frictional and pressure drag dominance on 2 given
bodies
Pressure drag comes from the eddying motions that are set up in
the fluid by the passage of the body. The wake is very
small, and the drag is dominated by the viscous
friction inside the boundary layers. However, as the angle
of attack increases, the pressure gradients on the airfoil
increase in magnitude.

406. Torsional stress variation across the circumference of

a cylinder and for rectangular cross-section.
Dependent on areal moment of inertia

407. Theories used in FEM softwares

Generally, Galerkin’s method and shape functions are used to
frame the backend of a FEM software but it also varies
from software to software.

408. Control surfaces in aircrafts

110
 409. Boundary layer flow and thickness
Boundary layer, in fluid mechanics, thin layer of a flowing gas or
liquid in contact with a surface such as that of an airplane
wing or of the inside of a pipe. The flow in such boundary
layers is generally laminar at the leading or upstream
portion and turbulent in the trailing or downstream
portion.

410.Airfoil characteristics and features, Cl vs AOA graph

411. Components and working of gas turbine engines

111
 412. What is Spot welding?
Spot welding (or resistance spot welding) is a type of electric
resistance welding used to weld various sheet metal
products, through a process in which contacting metal
surface points are joined by the heat obtained from
resistance to electric current.

413. What is galling?

Galling is a form of wear caused by adhesion between sliding
surfaces. When a material galls, some of it is pulled with
the contacting surface, especially if there is a large amount
of force compressing the surfaces together.

414. What is Kanban?

Kanban (signboard or billboard in Japanese) is a scheduling system
for lean manufacturing and just-in-time
manufacturing (JIT). Taiichi Ohno, an industrial
engineer at Toyota, developed kanban to improve
manufacturing efficiency. Kanban is one method to achieve
JIT. The system takes its name from the cards that track
production within a factory. For many in the automotive
sector, kanban is known as the "Toyota nameplate
112
 system".

415. What is Rapid Prototyping?

Rapid prototyping (RP) has emerged as a key enabling technology,
with its ability to shorten product design and development
time. Rapid prototyping is a technology for quickly
fabricating physical models, functional prototypes and
small batches of parts directly from computer-aided design
(CAD) data.

416.What is 3D Printing?
The 3D printing process builds a three-dimensional object from
a computer-aided design (CAD) model, usually by
successively adding material layer by layer, which is why it
is also called additive manufacturing, unlike conventional
machining, casting and forging processes, where material
is removed from a stock item (subtractive manufacturing)
or poured into a mold and shaped by means of dies,
presses and hammers.

417. Application of bearings

As they can tolerate limited speeds, spherical bearings are used in
vibrators, shakers, conveyors, speed reducers,
transmissions, and other heavy machinery.
Spherical bearings can accommodate a shaft or rod with
varying misalignment. They consist of a plain bearing, with
a ball bushing, inside a cylindrical housing.

418.Hookes law
Hooke's law is a law of physics that states that the force (F)
needed to extend or compress a spring by some distance
(x) scales linearly with respect to that distance—that

113
 is, where k is a constant factor characteristic of the spring
(i.e., its stiffness), and x is small compared to the total
possible deformation of the spring. The law is named after
17th-century British physicist Robert Hooke. He first stated
the law in 1676 as a Latin anagram. He published the
solution of his anagram in 1678 [3] as: ut tensio, sic vis ("as
the extension, so the force" or "the extension is
proportional to the force"). Hooke states in the 1678 work
that he was aware of the law already in 1660.

419.Universal joints
A universal joint is a mechanical device that allows one or more
rotating shafts to be linked together, allowing the
transmission of torque and/or rotary motion. It also allows
for transmission of power between two points that are not
in line with each other.

420. Kinematics of machinery – different linkages

kinematics or it is a subject which deals with the study of motion.
and without considering the forces acting.

421. 4 bar linkages

A four-bar linkage, also called a four-bar, is the simplest movable
closed-chain linkage. It consists of four bodies,
called bars or links, connected in a loop by four joints.
Generally, the joints are configured so the links move in
parallel planes, and the assembly is called a planar four-bar
linkage.

422.Whitworth quick return mechanism

114
 423.Constricted motion
Constrained Motion and Constraint Forces. Constrained
motion results when an object is forced to move in a
restricted way. For example, it may have to move along a
curved track, to slide on a table that may accelerate
upwards, to stay in contact with an accelerating wedge,
etc.

424. Mohr’s diagram

115
 425.Thermodynamic charts
● PV diagram.
● T–s diagram.
● h–s (Mollier) diagram.
● Psychrometric chart.
● Cooling curve.
● Indicator diagram.
● Saturation vapor curve.
● Thermodynamic surface.

426. Different stress – strain situations

There are five fundamental types of loading: compression, tension,
shear, torsion, and bending. Stress is the force applied to a
material, divided by the material's cross-sectional
area. Strain is the deformation or displacement of material
that results from an applied stress.

116
 427.What are the important mechanical operations in
cement mills?
Drilling and blasting
Loading
Haulage
Crushing

428. Draw Projection Views of the given component

N/A

429. Describe your design project

430. What is PLM?

Product Lifecycle Management refers to the handling of a good as
it moves through the typical stages of its product life:
development and introduction, growth, maturity/stability,
and decline. This handling involves both the manufacturing
of the good and the marketing of it.

431. Difference between mechanism and machine

Mechanism is a combination of various links which are capable of
having relative motion with respect to one
aother. Machine is the combination of number of
such mechanisms used to carry out a particular tasks.

432.Why is petrol more expensive than diesel?

Diesel fuel is heavier and less volatile than gasoline, which makes it
simpler to refine from crude oil. As a result, diesel tends to
be cheaper than gasoline in most countries around the
world.

433.Draw Iron carbon Diagram and explain.

117
 434. How to make steel more tough and hard.
By performing it heat treatment

435.Draw diesel and otto cycle, and compare their

efficiencies

118
 436. What is the difference between stress and pressure?
Stress is the internal resistance offered by a body undergoing
deformation where as Pressure is the force acting per unit
area.

437.Newton’s laws
Newton's first law states that every object will remain at rest or in
uniform motion in a straight line unless compelled to
change its state by the action of an external force. 
The second law explains how the velocity of an object changes
when it is subjected to an external force.
The third law states that for every action (force) in nature there is
an equal and opposite reaction.

438. Will two balls of different masses dropped from same

height reach at the same time?
Yes

119
 439. Braking system in train engine, locations of them
The vast majority of the world's trains are equipped with braking
systems which use compressed air as the force to push
blocks on to wheels or pads on to discs. These systems are
known as "air brakes" or "pneumatic brakes".
They are present on the wheels.

440. Inertia
Force due to self-weight under motion.

441. Differential of an automobile.

It is a combination of gears which facilitates uniform turning of
each wheel when an automobile takes a turn.

442. Deformation of two bodies of different material

supported by simply supported ends by a force applied
vertically.(variable support conditions-spring support,
conical cylinder support.

443. Stiffness of bar element.

444. Free body diagrams

a free body diagram (force diagram, or FBD) is a graphical
illustration used to visualize the applied forces, moments,
and resulting reactions on a body in a given condition.
120
 445. What will happen if diesel is used in petrol engine and
what is the basic difference between the two engines
Petrol has higher auto ignition temperature and it won't burn at
the compression ratio of a diesel engine without external
help. So, the engine won't run. Whereas when you use
diesel in petrol engine, it's dangerous. Diesel burns with
more power and it may damage the engine partly or
completely.

446. Rake angle

The rake angle is the angle of the surface of a cutting tool tip over
which the removed chips flow. The rake angle is
the angle between the front or cutting face of the tool and
a line perpendicular to the workpiece.

447. Broaching tool, its comparison with reamer and

drilling
Broaching is a machining process that uses a toothed tool, called
a broach, to remove material. 
A broach is tapered, and can ream various size holes. A reamer is
not tapered, and makes a hole precisely sized for the
bushing-diameter it goes with.

448. Centering of lathes.

Centering Operation Lathe Points : Centering Operation Lathe, Cen
tering process Lathe Centering is the process of hold the
job in a work holding device chuck, drive plate, and face
plate on center of lathe machine. It is required to turn any
job concentric to lathe centers for cylindrical machining.

449. Laws of thermodynamics

121
 Zeroth law of thermodynamics – If two thermodynamic
systems are each in thermal equilibrium with a third, then
they are in thermal equilibrium with each other.
First law of thermodynamics – Energy can neither be
created nor destroyed. It can only change forms. In any
process, the total energy of the universe remains the
same. For a thermodynamic cycle the net heat supplied to
the system equals the net work done by the system.
Second law of thermodynamics – The entropy of an
isolated system not in equilibrium will tend to increase
over time, approaching a maximum value at equilibrium.
Third law of thermodynamics – As temperature
approaches absolute zero, the entropy of a system
approaches a constant minimum.

450. Entropy
entropy is an extensive property of a thermodynamic system. It is
closely related to the number Ω of microscopic
configurations that are consistent with the macroscopic
quantities that characterize the system.

451. Knuckle joint

A knuckle joint is a mechanical joint used to connect two rods
which are under a tensile load, when there is a requirement
of small amount of flexibility, or angular moment is
necessary. There is always axial or linear line of action of
load.

452.Product lifecycle diagram and various activities related

to it

122
 453.What is the principle of operation of a centrifugal pump
?
it means when a mass of liquid is rotating by an external torque,
the rise in pressure head of the rotating liquid takes places.
The rises in pressure head at any point is directly
proportional to the velocity of the liquid at that point.

454. What is centrifugal force ?

 the centrifugal force is an inertial force that appears to act on all
objects when viewed in a rotating frame of reference. It is
directed away from an axis passing through the coordinate
system's origin and parallel to the axis of rotation.

455.A steel ball and a plastic ball of same dimensions are

dropped from a certain height ? Which will reach the
ground faster ? What if I do the same experiment in
vacuum ?
Both will reach at same time.

123
 456. Deflection of an I-Beam is greater or a simple
rectangular beam is greater ?
Rectangular beam. Since its moment of Inertia is greater.

457.Petrol or diesel engine ? Which has a greater power ?

Petrol engine will have higher power than diesel engine because it
can run at much higher RPM and as power is directly
proportional to the RPM hence, petrol engine will
produce more power, although diesel engine
has more Torque, but it will not produce same amount
of power as petrol engine, as it has low RPM.

458. Can stress, strain concepts be physically felt ?

Yes

459. Explain the working principle behind RAMJET (Gas

Dynamics).
The air entering into ram jet with supersonic speed is slowed down
to sonic velocity in the supersonic diffuser ,increasing air
pressure. The air pressure is further increase in the
subsonic diffuser increasing also the temperature of air.
The diffuser section is designed to get correct ram effect.
it’s job is to decrease the velocity & increase pressure of
incoming air. The fuel injected into combustion chamber is
burned with help of flame igniter. The high pressure and
high temperature gases are passed through the nozzle
converting into pressure energy into kinetic energy. The
high velocity gas leaving the nozzle provide required
toward thrust to.

460. Explain Rankine cycle, then refrigeration cycle and

explain each and define enthalpy.

124
 The Rankine cycle is a model used to predict the performance of
steam turbine systems. It was also used to study the
performance of reciprocating steam engines. The Rankine
cycle is an idealized thermodynamic cycle of a heat engine
that converts heat into mechanical work while undergoing
phase change.
Thermodynamic heat pump cycles or refrigeration cycles are the
conceptual and mathematical models for heat pumps and
refrigerators. A heat pump is a mechanical system that
allows for the transference of heat from one location at a
lower temperature to another location at a higher
temperature.
Enthalpy, a property of a thermodynamic system, is equal to the
system's internal energy plus the product of its pressure
and volume. In a system enclosed so as to prevent mass
transfer, for processes at constant pressure, the heat
absorbed or released equals the change in enthalpy. 

461.Would you chose a RAMJET for a commercial aircraft?

No, Ramjet engines are used for hypersonic Planes

462. What is the difference between Up Milling and Down

Milling?
Up Milling

Down Milling

In up milling the cutter rotates against In Down milling, the cutter rotate
direction of feed. direction of feed.

It is also known as conventional milling. It is also known as climb milling.

In this, chip width size is zero at initial cut In this cutting process, chip s

125
 and increase maximum at start of c
with feed. and decrease with the feed. It is zero
the end of feed.
It is maximum at the end of feed.

In this process, heat is diffuse to the In down milling most of heat diffuse
work piece which the chip does n
causes the change in metal properties. change the work piece properties.

In up milling, tool wear is more because In this, tool wear is less compare to th
the tool runs up milling, du
against the feed. to the cutter rotate with the feed.

Tool life is low. Tool life is high.

The cutting chips are carried upward by The chips are carried downward by th
the tool so known tool so known
as up milling. down milling.

The cutting chips fall down in front of The cutting chips fall down behind th
the cutting tool tool. This giv
which again cut the chips cause less better surface finish.
surface finish.

Due to upward force by tool, high In down milling, downward force act o
strength zig and fixture work piece norm
required to hold the work piece. zig and fixture required.

It is the traditional way of cutting the It is non-traditional way, but now day
work piece. down milling use
more than up milling.

High quality cutting fluid is required In this process heat does not diffuse
because heat the work piec
diffuse in the work piece. so simple cutting fluid is required.

126
 It required high cutting force compare to It required low cutting force.
down milling.

463. What are Jigs and Fixtures? What is the Difference

between them?
 a jig is a type of tool used to hold and support the workpiece but
in addition to this, Jig also control the location or motion of
tool. On the other hand, a fixture is a support or work
holding device used to hold work in place.

464. Gave me a Top view and Front view and told to draw
Isometric or side view.

465. What is Laminar Flow?

Laminar flow is a flow regime characterized by high momentum
diffusion and low momentum convection. When a fluid
is flowing through a closed channel such as a pipe or
between two flat plates, either of two types of flow may
occur depending on the velocity and viscosity of the
fluid: laminar flow or turbulent flow.

466. Draw the velocity profile of an Aerofoil.

127
 467. Basics of pro e, Engineering drawing?

468. How do you bend the pipes in the radiator of a

refrigerator?

469. What is Bernauli’s Theorm?

in fluid dynamics, Bernoulli's principle states that an increase in the
speed of a fluid occurs simultaneously with a decrease in
static pressure or a decrease in the fluid's potential energy.

470. What is viscosity, its applications, dependence on

temp?
Drug companies manufacture medicines, such as cough syrup, that
have a high viscosity yet are still drinkable, in order to coat
and soothe the throat.

471. How do you prevent sagging of belts?

eliminate belt sag by ensuring that the stringer support structures
are straight and parallel. Footings must provide a rigid
128
 support structure to prevent stringer deflection.

472.Boilers used in power plants

There are mainly two types of boiler – water tube boiler and fire
tube boiler.

473.Power generation cycle

A combined cycle power plant is an assembly of heat engines that
work in tandem from the same source of heat, converting
it into mechanical energy. On land, when used to make
electricity the most common type is called a combined
cycle gas turbine plant.

474. Adjustment of length of conveyors in power plants?

There is a wide variation in the belt tension. Manual screw type
takeups also require a careful operator to observe when
additional takeup (readjustment) is required.

475.Materials used for conveyors

Conveyor belts are made out of out of five main materials:
● Thermoplastics
● Metal
● Rubber
● Fabric and leather
● Plastics include polyester, polyvinyl chloride,
silicone and polyethylene.
 
476. Pulley adjustment for conveyors
Remove the right bearing to the exterior to make the head roller
advance in a position that will tighten the belt. Put the left
one in to move the head roller in a position that will
slacken the belt. Make an adjustment, and then look at

129
 the belt. Make a new adjustment and examine again.

477.Types and design of heat exchangers

Shell and Tube Heat Exchangers
Other design characteristics available for this type of heat
exchanger include finned tubes, single- or two-phase heat
transfer, counter current flow, cocurrent flow, or crossflow
arrangements, and single, two, or multiple pass
configurations.

478. Why counter flow preferred over parallel flow?

Counter flow heat exchangers are inherently more efficient
than parallel flow heat exchangers because they create a
more uniform temperature difference between the
fluids, over the entire length of the fluid path.

479. Why do we need high pressure for injecting fuel into

the combustion chamber?
The main philosophy of having a injection pressure is to
inject a fuel in atomized form for high performance of a
vehicle. The more it atomizes the more particles get
ignited, the less fuel is consumed ultimately fuel
usage is reduced In other words fuel efficiency is increased.

480. Camber, caster angles, where are they used, why are
they used?
Camber angle is the angle made by the wheels of a vehicle;
specifically, it is the angle between the vertical axis of the
wheels used for steering and the vertical axis of the vehicle
when viewed from the front or rear. It is used in the design
of steering and suspension.
The caster angle or castor angle is

130
 the angular displacement of the steering axis from the
vertical axis of a steered wheel in a car, motorcycle,
bicycle, other vehicle or a vessel, measured in the
longitudinal direction.

481.Stresses experienced by cycle spokes.

Pretensioning also prevent the bottom spokes from poking (due
to compression) into the tier tube and puncturing it.
Therefore, spokes are subjected to tensile stress. At high
speeds, there are additional tensile stress on spokes due to
the centrifugal force offered by the wheel rim.

482. Force deflection diagram for a

● beam having knife edge on both ends and a point
force at the center
● beam having cylindrical edges on both ends and a
force at the center

483. Safety system in a vehicle, ECU, sensors

An electronic control unit (ECU) is any embedded system in
automotive electronics that controls one or more of the
electrical systems or subsystems in a vehicle.
Passive Safety Systems play a role in limiting/containing the
damage/injuries caused to driver, passengers and
pedestrians in the event of a crash/accident. Airbags,
Seatbelts, Whiplash Protection System etc. are
common Passive Safety Systems deployed in vehicles these
days.

484. A bush and pin is given. The pin should slide in and
turn. What fit do you use?

131
 485. What process you use to make a pin from scratch( a
cylinder)
Blunt wire with an international steel regulation of ISR 9002 is
generally used to make straight pins. To create the wire, a
bar of steel is heated to a temperature of 2,200°F (1,200°C),
rolled into a long thin rod, coiled, and then allowed to cool.
The heating causes an oxide coating to form on the wire.

486. How will you convert a rotary motion of a gear into

linear motion
Using Rack and Pinion mechanism.

487. A rectangular drawing with axis is shown how will you

show that it’s a cylinder
Use symbol ‘phi’ to the dimension of smaller edge

488. Why are tires black?

Cars themselves come in dozens of hues, but not tires. The rubber
that tires are sourced from is a milky white color, but
carbon black is added to the rubber as a stabilizing
chemical compound and makes the tire black.
Carbon black is combined with other polymers to create
the tire's tread compound.

489. Is fan a turbine?

Yes

490. In Pelton, why the 2 notches on top? Draw cut section

of Pelton wheel.

132
 491.Refrigerator in a sealed room. What would happen?
The room gets heated up.

492. Draw aerofoil. Why aerofoil? How does it generate

lift?

493. What is an overdrive?. Explain the mechanism of

overdrive?
Overdrive is the operation of an automobile cruising at sustained
speed with reduced engine revolutions per minute, leading

133
 to better fuel consumption, lower noise, and lower wear.
Use of the term is confused, as it is applied to several
different, but related, meanings.

494. What is meant by Gyroscopic torque ?

Gyroscopic Effect is the phenomenon which comes in the
case of rotational body, disc or any other object. Each of
the rotational object has its own rotational axis about
which it decides its Axis of Orientation. This axis of
orientation remains steady as the Principle of Angular
Momentum Conservation is applied, which states that the
angular momentum remains constant. Now, even little
deviation of the axis of rotation from the axis of
orientation creates an restoring torque, which tries to
oppose or restore the axis of rotation. This torque is
known as the Gyroscopic Torque.

495. When you are riding a bi-cycle how would you turn if
your hands do not catch the handle bars?
By bending in the direction I want to turn.

496. Explain the functions of a Gear Box?

Alter the speed and torque.

497. What is meant by whirling of shaft ? How would you

rectify ?
Whirling speed is also called as Critical speed of a shaft. It
is defined as the speed at which a rotating shaft will tend
to vibrate violently in the transverse direction if
the shaft rotates in horizontal direction. In other words,
the whirling or critical speed is the speed at which

134
 resonance occurs.
To reduce excessive shaft deflection:
● Avoid operating speeds near the critical shaft speed,
where the shaft vibrates at its natural frequencies.
● Ensure the shaft is concentric, where its centre of
mass rotates about its geometric centre.

498. Other than cast iron, what material is used for making
Engines?
Alloy and structural steels, and aluminum alloys.

499. What material is used for making Carburetor?

The main structure and largest component of the carburetor is the
molded body made from a lightweight alloy or aluminum.
The stationary body is under little stress and pressure,
therefore, stronger metals are unnecessary. The moving
pieces of a carburetor are manufactured from steel or
stainless steel.

500. State the second law of thermodynamics?

The second law of thermodynamics states that the total entropy of
an isolated system can never decrease over time, and is
constant if and only if all processes are reversible. Isolated
systems spontaneously evolve towards thermodynamic
equilibrium, the state with maximum entropy. 

501. How is the tool locked in the spindle in CNC machine?

The part of the machine tool that spins or rotates. On the mill,
the spindle holds the cutting tool. The long, narrow
portion of a tool holder that is typically shaped like a cone.
Tapered shanks are the most common shape for a mill tool
holder.

135
 502.What are the processes involved and how would you
estimate the cost of manufacture of an Aluminum
block?

503. How is stainless steel manufactured?

To make stainless steel, the raw materials—iron ore, chromium,
silicon, nickel, etc. —are melted together in an electric
furnace. This step usually involves 8 to 12 hours of intense
heat.

504. What are the different kinds of Centrifugal pump?

centrifugal pumps can be categorized in different groups: Radial
flow pumps, mixed flow pumps and axial flow pumps.
Radial flow pumps and Semi-axial flow pumps are the most
common types used.

505. What are the differences between Forging and

Casting?

136
 506. What is the composition of stainless steel?
Stainless steels are steels containing at least 10.5% chromium, less
than 1.2% carbon and other alloying elements.

507.What is TIG welding? Where is it used?

TIG Welding, also known as Gas Tungsten Arc Welding (GTAW), is a
process that joins metals by heating them with an arc
between a tungsten electrode (non-consumable) and the
work piece. The process is used with a shielding gas and
may also be used with or without the addition of filler
metal.

508. What is a gyroscope?

A gyroscope is a device used for measuring or maintaining
orientation and angular velocity. It is a spinning wheel or

137
 disc in which the axis of rotation is free to assume any
orientation by itself.

509. Why TIG welding is used for welding stainless steel

compared to Arc welding?
TIG welding uses less amperage when compared with other
process. As TIG welding uses less amperage,
the welder easily accomplishes the task. In fact, less
amperage TIG welding is a boon alloys and metals, where
high current arc is not recommended.

510. In Hydraulic press what are the possible operations? In

Mechanical press what are the possible operations?
Hydraulic presses are commonly used for forging, clinching,
molding, blanking, punching, deep drawing, and metal
forming operations
Mechanical presses to produce the sheet metal components in
large volumes. Generally, press tools are categorized by
the types of operation performed using the tool, such as
blanking, piercing, bending, forming, forging, trimming etc.

511. What is corrosion? Will aluminum corrode?

Corrosion is a natural process that converts a refined metal into a
more chemically stable form such as oxide, hydroxide, or
sulfide. It is the gradual destruction of materials (usually a
metal) by chemical and/or electrochemical reaction with
their environment.
Aluminum corrodes but it does not rust. Rust refers only to iron
and steel corrosion. Aluminum is actually very prone
to corrosion. However, aluminum
corrosion is aluminum oxide, a very hard material that
actually protects the aluminum from further corrosion.

138
 512. What is anodizing?
Anodizing is an electrolytic passivation process used to increase
the thickness of the natural oxide layer on the surface of
metal parts. The process is called anodizing because the
part to be treated forms the anode electrode of an
electrolytic cell.

513. What is clausius statement ? Provide an example

Clausius introduced the word entropy, referring to the ratio of
heat flux and temperature. Clausius statement of the
second law is: “ It is not possible to construct a device that
operates in a cycle and whose sole effect is to transfer heat
from a colder body to a hotter body.”

514. What coating is used for glass door frames to prevent

them from rusting ?

515. What is Normal Distribution ?

In probability theory, a normal distribution is a type of continuous
probability distribution for a real-valued random variable.
The general form of its probability density function is The
parameter is the mean or expectation of the distribution;
and is its standard deviation.

516. What would be the specification of an engine if you

prefer to buy one?
Engine Type –V8 6 cylinder
Capacity – 1.3lit
Speed Transmissions – 6

139
 517. What are the different types of casting that you are
aware of?
Permanent, Die, Centrifuge, Continuous.

518. What is the difference between hot chamber casting

and cold chamber casting (types of dye casting)?
519. Hot-Chamber Die Casting
Hot-chamber die-casting uses the same process previously
mentioned — molten metal is forced through the cavity of a
pre-shaped mold using pressure. The defining characteristic of
hot-chamber die-casting is that metal is heated inside the
casting machine rather than a separate machine or furnace.
Cold-Chamber Die Casting
Based on its name, you may assume that cold-chamber die-
casting involves forcing cold metal through the cavity of a
mold, but this is not necessarily true. Cold-chamber die casting
still requires the use of molten metal that’s forced into a mold.
The difference between these two processes is that hot-
chamber die casting heats metal inside the casting machine,
whereas cold-chamber die-casting involves heating metal in a
separate furnace and then transferring the newly molten metal
into the casting machine.

520.What are the metals, which can be casted in hot

chamber and cold chamber?
Typically, this will include metal alloys of aluminum, brass and
copper. Cold chamber machinery requires additional
equipment — usually an outside furnace and a ladle to
pour the metal into the machine — for die-casting.

521. What kind of casting is used for making camshafts?

140
 The camshaft is made from Chilled iron castings, because this
material has far superior wear characteristics than any
other material.

522. Tell me some hardness tests?

● Rockwell Hardness test
● Brinell Hardness test
● Knoop Hardness Test.
● Vickers Hardness Test.

523.What is the function of a riser in sand casting?

A riser, also known as a feeder, is a reservoir built into a
metal casting mold to prevent cavities due to shrinkage.
Most metals are less dense as a liquid than as a solid
so castings shrink upon cooling, which can leave a void at
the last point to solidify.

524.Why surface treatment is needed?

Surface treatment is a possible way to obtain sufficient resistance against
environmental attack, including oxidation, without spoiling
the required mechanical properties of the substrate.

525.What is the reason for internal blow holes in casting?

Gas porosity occurs when the metal traps gas (most often nitrogen,
oxygen or hydrogen) during casting. When the casting cools and
solidifies, bubbles form because the solid form of the metal
cannot hold as much gas as the liquid form. These bubbles appear
on a casting as rounded, circular cavities or holes.

526.What is iron carbon diagram?

The iron-carbon diagram (also called the iron-carbon phase or
equilibrium diagram) is a graphic representation of the respective

141
 microstructure states depending on temperature (y axis)
and carbon content (x axis). The actual iron-carbon diagram is far
larger than the part shown here.

527.What is the difference between Casting & Machining?

One advantage of using CNC machining is that it is better for low volume
parts since no tooling cost is required. Die casting is the preferred
option if you're looking for a high volume of consistent, reliable
parts. On the other hand, if your part has a lot of surface detail,
you may prefer to use die casting.

528.What is Conduction?
Conduction is the movement of heat or electricity through a material
without any perceptible motion of the material.

529.What is Convection?
Convection occurs when heat is transferred through a gas or liquid by the
hotter material moving into a cooler area. In meteorology, it is the
transfer of heat and other atmospheric properties by the
movement of masses of air, particularly in an upward direction.

530. What is Radiation?

Radiation is often categorized as either ionizing or non-
ionizing depending on the energy of the radiated particles.
Ionizing radiation carries more than 10 eV, which is enough
to ionize atoms and molecules and break chemical bonds.

531. How do you define a fluid?

A substance that has no fixed shape and yields easily to external pressure;
a gas or (especially) a liquid.

532.What are the properties of fluids?

142
Temperature, density, pressure, and specific enthalpy are the
thermodynamic properties of the fluids.

533.What are the types of forces that act on static fluids?

● Gravitational Force
● Hydrostatic Pressure
● Surface Tension

534.What is the principle behind the nozzle?

Nozzles are frequently used to control the rate of flow, speed, direction,
mass, shape, and/or the pressure of the stream that emerges
from them. In a nozzle, the velocity of fluid increases at the
expense of its pressure energy.

535.How is hydrogen produced?

As of 2018, the majority of hydrogen (∼95%) is produced from fossil fuels
by steam reforming of natural gas, partial oxidation of methane
and coal gasification. Other methods of hydrogen production
include biomass gasification and electrolysis of water. ...
Pure hydrogen is not generally found in large quantities on Earth.

536. What is the efficiency of an Engine?

537.What are the differences between an IC Engine and

Propulsion Engine?
IC engine does not have turbine and compressor in construction while it is
present in propulsion engine.

538. What are the devices that are used to measure

pressure?
Instruments used to measure and display pressure in an integral unit are
called pressure meters or pressure gauges or vacuum gauges. A

143
 manometer is a good example, as it uses the surface area and
weight of a column of liquid to both measure and
indicate pressure.

539. How would you measure pressure using a

manometer?
An visual application is shown below

540. What is the effect of temperature on the viscosity of a

fluid?

144
 541. What is the effect of temperature on Vapour pressure?
The pressure exhibited by vapor present above a liquid surface is known
as vapor pressure. As the temperature of a liquid increases, the
kinetic energy of its molecules also increases.

542.What is Top Dead Center(TDC) and Bottom Dead

Center(BDC)?
Dead centres are the farthest and nearest positions of a piston from the
crankshaft in an IC engine. So the Top Dead Centre (TDC) is the
topmost position of the piston inside the cylinder and Bottom
Dead Centre (BDC) is the bottommost position of the piston
inside a cylinder.

543.Define what is meant by specific gravity and viscosity of

a fluid?
The specific gravity of an object is the ratio between the density of an
object to a reference liquid. Usually, our reference liquid is water,
which has a density of 1 g/mL or 1 g/cm^3.

145
 544. What is the function of a Gear Box?
The gearbox is part of the car's powertrain (power transmission)
between engine and drive wheels. The function of the gearbox is
to change the gear ratio depending on speed and power
requirements. The car has an eight-speed automatic gearbox.

545.Explain pressure loss that occurs due to friction in pipes

In fluid flow, friction loss (or skin friction) is the loss of pressure or
“head” that occurs in pipe or duct flow due to the effect of the
fluid's viscosity near the surface of the pipe or duct.

546. What is flow rate?

Volume of fluid flow with respect to time is called flow rate.

547.What is momentum equation?

548. Which is more effective? Gear Drive or Belt Drive

Gear Drive

549. What do you understand by Manufacturing Process?

Manufacturing is the production of products for use or sale using labor

146
 and machines, tools, chemical or biological processing or
formulation and is the essence of secondary industry.
Manufacturing engineering or manufacturing process are the
steps through which raw materials are transformed into a final
product.

550. What are CNC machines?

CNC machining is a manufacturing process in which pre-programmed
computer software dictates the movement of factory tools
and machinery. The process can be used to control a range of
complex machinery, from grinders and lathes to mills and routers.

551. What is the program used in CNC machine?

NC part programming, G and M codes.

552.Make a process flow chart of any manufacturing

process that you know

147
 553.What are the makes available for CNC cutting tools?
Cutting tools are available in three basic material types: high-speed steel,
tungsten carbide, and ceramic. High-speed steel is generally used
on aluminum and other nonferrous alloys, while
tungsten carbide is used on high-silicon aluminums, steels,
stainless steels, and exotic metals.

554.How would you calculate the viscosity of a fluid?

One way to think about viscosity is that it is the amount of force required
to get that substance moving. It is the force per unit area,
so viscosity is equal to force divided by area. With an
ideal fluid (called a Newtonian fluid), it is also directly
proportional to what is called the shear rate.

555.How would you calculate the discharge of a fluid?

Using a venturi meter, orifice meter, v-notch, rectangular notch, etc.

556. What is recrystallization temperature?

Recrystallization temperature is a particular temperature point below the
melting point of a metal (or material). This is because the grains
at this temperature, make the metal behave in plastic manner,
allowing them to deform greatly for very less force application.

557.State the law of conservation of energy?

Energy can neither be created nor destroyed but can be transformed
from one form to another.

558. What is a turbo machine?

A turbomachine is a device where mechanical energy in the form.
A turbomachine is a device where mechanical energy in the form.
of shaft work, is transferred either to or from a continuously

148
 flowing fluid by the dynamic action of rotating blade rows.

559. What are the losses that could occur in a turbo

machine?
● Three-dimensional profile losses.
● Three-dimensional shock losses.
● Secondary flow.
● Endwall losses in axial turbomachinery.
● Tip leakage flow losses.

560. Provide the proper balanced chemical equation for

rusting?

561. What is Casting? What are the various types of Casting?

Examples are Centrifugal casting, Extrusion, Forging, Full mold casting,
Investment casting, Permanent or Gravity Die casting, Plaster
mold casting, Sand Casting, Shell Mold casting. The method to be
used depends upon the nature of the products to be cast.

562.What is meant by degrees of freedom?

Degrees of freedom encompasses the notion that the amount of
independent information you have limits the number of

149
 parameters that you can estimate. Typically, the degrees of
freedom equal your sample size minus the number of parameters
you need to calculate during an analysis.

563. Why is the shape of a water droplet spherical in

shape?
Due to the effect of surface tension

564. What are the various machining process that you are
aware of?
Drilling, milling, boring, turning, counter-sinking, counter-boring, grinding,
shaping, honing etc.

565. What is quick return mechanism in a Shaping

machine?

566. What is the difference between Shaping and Planing?

Shaping is one machining operation where workpiece is held stationary
while cutting tool (ram) is reciprocated across the work. Planing is
similar machining operation but here the cutting tool remains
stationary while workpiece (worktable) is reciprocated under the
cutter.

567.What are the various types of milling?

150
face milling, end milling, side milling, ram milling, horizontal milling,
vertical milling etc.

568. What are the various types of Grinding?

surface grinding, cylindrical grinding, internal grinding, special grinding,
creep feed grinding etc.

569. What are the differences between drilling, boring and

reaming?

570.What is meant by a through hole and a blind hole?

A blind hole refers to a hole that is reamed, drilled, or milled to a specified
depth without breaking through to the other side of the
workpiece. The etymology is that it is not
possible to see through a blind hole. Other types of holes also
include through holes, and clearance holes.

571. What are the operations that are possible in a Lathe?

151
 572.Under what circumstances will you go for : Shell
Moulding, Green Sand Moulding and Die Casting?

573.Draw a Gear and label the parts

574.What is Corrosion? How does it occur? What are the

various methods to prevent it?
152
Turn to non-corrosive metals such as aluminum and stainless
steel. Keep the area around the metal surface dry. Use drying
agents and moisture barrier products. Make sure underground
piping is laid in a layer of backfill, such as limestone.

575.What are the various plating methods to stop

corrosion?
Electroplating, galvanising etc

576.What is Investment Casting?

Investment Casting is a metal casting process which employs an
expendable pattern and one piece non metallic mould. Although
all metals, namely ferrous as well as non-ferrous can be casted by
this process, it is most suitable for expensive, hard and high
strength metals and alloys, which are difficult to machine.

577.What are the basic differences between a Diesel Engine

and a Petrol Engine?
In a petrol engine , there is a spark plug and air fuel mixture is sent
through the manifold while in a diesel engine, only air is sent
through the manifold and fuel injector is present for spraying the
fuel.

578.What is meant by the efficiency of an Engine?

brake power to the total energy that the fuel can produce is the
efficiency.

579.What are the basic differences between a 2-stroke and a

4-stroke engine
2-stroke engines have only ports and not valves.

580. What is the type of gear boxes used in automobiles?

153
Automatic transmission is generally subdivided into two types:
Epicyclic gear box: This type of gear box uses no sliding dogs
or gears to engage but different gear speeds are obtained by
merely tightening brake bands on gear drum. It consists of a
ring gear annular wheel, sun gear and planet gears with carrier.

581. What is the 5th gear (overdrive)?

Overdrive is the operation of an automobile cruising at sustained speed
with reduced engine revolutions per minute (RPM), leading to
better fuel consumption, lower noise, and lower wear. Use of the
term is confused, as it is applied to several different, but related,
meanings.

582.Explain Bernoulli's principle and what are its

applications?
Bernoulli's principle can be applied to many everyday situations. For
example, this principle explains why airplane wings are curved
along the top and why ships have to steer away from each other
as they pass. The pressure above the wing is lower than below it,
providing lift from underneath the wing.

583. How is roughness tested?

Roughness can be measured by manual comparison against a
"surface roughness comparator" (a sample of known
surface roughness), but more generally a surface profile
measurement is made with a profilometer.

584. Define the terms Yield Strength, Tensile Strength and

Impact Strength
The stress at which a specific amount of plastic deformation is produced
is called yield strength. Tensile strength is a measurement of the
force required to pull something such as rope, wire, or a

154
 structural beam to the point where it breaks. The impact
strength of a material is defined as its capability to resist a sudden
applied load or force. It is normally conveyed as the amount of
mechanical energy absorbed in the process of deformation under
the applied impact loading and is expressed as energy lost per
unit of thickness ft.lb/in or J.cm.

585. A piece of metal is taken from a tropical climate to say

antartica,What happens to the metal? Does it become
stronger or weaker? Explain your answer

586. What is Charpy V-notch's test?

The Charpy impact test, also known as the Charpy V-notch test, is
a standardized high strain-rate test which determines the amount
of energy absorbed by a material during fracture. Absorbed
energy is a measure of the material's notch toughness.

587.While head being the same and the Input pressure of

the water being the same how could the efficiency of 2
turbines vary?

588. What are the parameters under consideration for the

design of a turbine blade?
The design parameters for the blade optimisation include design wind
speed, design tip speed ratio, and design attack angle. A series
of design case studies using various design parameters are
investigated for the wind turbine blade design.

589. Explain in detail the design of a weld joint

155
 590. What are the differences between TIG & MIG welding?
The difference between the two is the way the arc is used. MIG (metal
inert gas) welding uses a feed wire that constantly moves
through the gun to create the spark, then melts to form
the weld. TIG (tungsten inert gas) welding uses long rods to fuse
two metals directly together.

591. In an organization who is responsible for Quality?

The quality of the product is dependent on the quality of the process,
input material, the equipment, staff, systems, data, etcetera. So,
everybody is responsible for a part of the cake. Short answer:
personnel performing work affecting conformity to product
requirements are responsible for Quality.

592.Explain what welding mechanism you will use for

welding 2-10mm thick plates? What type of joint would
you make?
deep vee both edges so that a thickness of 3mm is left place a
clamp either side of the weld as when the plate is cooling , it will
156
 bend up at the joint pass weld over ensuring full penetration then
pass over more welds on each side of the first ensure full
penetration on each pass.

593. What is a heat affected zone?

In welding, the heat-affected zone (HAZ) is the area of base material,
either a metal or a thermoplastic, which is not melted but has had
its microstructure and properties altered by welding
or heat intensive cutting operations.

594. Explain the differences between a forged component

and a casting component?
Casting is the process where metal is heated until molten. While in
the molten or liquid state it is poured into a mold or vessel to
create a desired shape. Forging is the application of thermal and
mechanical energy to steel billets or ingots to cause the material
to change shape while in a solid state.

595. What did you observe in a forge shop?

A forge is a type of hearth used for heating metals, or the workplace
(smithy) where such a hearth is located. The forge is used by the
smith to heat a piece of metal to a temperature where it becomes
easier to shape by forging, or to the point where work hardening
no longer occurs.

596. What are the different type of lathes?

Speed Lathe Machine.
Engine Lathe Machine.
Bench Lathe Machine.
Toolroom Lathe Machine.
Capstan and Turret Lathe Machine.
Special purpose lathe machines.

157
 Automatic Lathe Machine.

597.What is tensile testing?

Tensile testing, also known as tension testing, is a fundamental materials
science and engineering test in which a sample is subjected to a
controlled tension until failure. ... Uniaxial tensile testing is the
most commonly used for obtaining the mechanical characteristics
of isotropic materials.

598. Which department would you choose to work in an

organization - Marketing, Design, R & D, Quality,
Production
Design or R&D

599. Draw and mark the nomenclature of a gear tooth

600. What inputs do you need to calculate the pitch circle

diameter of a gear?
Number of teeth, Module

601.What are the different types of carbide tip tool?

 Universal Tools offers carbide tipped tools which are available
in type drills, reamers, endmills, milling cutters etc
158
 602. Describe the main elements of a lathe? How would
you machine a component using the lathe?
Bed. It is the main body of the machine.
Tool post. It is bolted on the carriage.
Chuck. Chuck is used to hold the workspace.
Head stock. Head stock is the main body parts which are placed at
left side of bed.
Tail stock. Tail stock situated on bed.
Lead screw.
Legs.
Carriage.

603. What is the difference between a sheet and a plate?

Difference Between Sheet and Plate. Plate and sheet are words used to
describe the classification of metal depending upon its thickness.
While sheet metal is less than 3 mm thick, plate metal is obviously
thicker than 3 mm.

604. Draw the block diagram of the process flow and

explain the manufacturing of the pressure cooker in the
cooker factory that you had been for your in-plant
training

159
 605. What are the various Non-Destructive testing
techniques? Explain each technique
● Acoustic Emission Testing (AE)
● Electromagnetic Testing (ET)
● Ground Penetrating Radar (GPR)
● Laser Testing Methods (LM)
● Leak Testing (LT)
● Magnetic Flux Leakage (MFL)
● Microwave Testing.
● Liquid Penetrant Testing (PT)

606. What is a newtonian fluid?

A Newtonian fluid is a fluid in which the viscous stresses arising from its
flow, at every point, are linearly correlated to the local strain rate
—the rate of change of its deformation over time. Newtonian
fluids are the simplest mathematical models of fluids that account
for viscosity.

160
 607. What is Newton's law of viscosity?
Newton's viscosity law's states that, the shear stress between adjacent
fluid layers is proportional to the velocity gradients between the
two layers. The ratio of shear stress to shear rate is a constant, for
a given temperature and pressure, and is defined as
the viscosity or coefficient of viscosity.

608. What are the differences between translational flow

and irrotational flow?
If there is angular momentum of the fluid about any point, then
the flow is said to be rotational flow. In other words, if curl V is
not zero then flow is rotational. In irrotational flow, fluid particles
while flowing do not rotate about its own axis. The real
fluids(fluids having viscosity) have rotational flow.

609. What is Curl V ( Curl of the Velocity vector ) in

translational flow and rotational flow?
If there is angular momentum of the fluid about any point, then
the flow is said to be rotational flow. In other words, if curl V is
not zero then flow is rotational. Irrotational flow: This means that
there is no angular momentum of thefluid about any point.

610.What is Bernoulli's theorem?

the total mechanical energy of the flowing fluid, comprising the energy
associated with fluid pressure, the gravitational potential energy
of elevation, and the kinetic energy of fluid motion, remains
constant.

611. How is steel manufactured?

To make steel, iron ore is first mined from the ground. It is then smelted
in blast furnaces where the impurities are removed and carbon is

161
 added. In fact, a very simple definition of steel is "iron alloyed
with carbon, usually less than 1%."

612. How do you distinguish between roller contact bearing

and general bearing?
1.BALL as a rotating element
Point contact on raceway — lower friction — permit high RPM — but
carry lower radial load comparing to cylindrical roller
That’s why most of Electric motors (high RPM) contains with ball
bearing .
2.ROLLER as a rotating element
Line contact on raceway — high friction — running on low RPM compare
to ball — but carry Higher radial load comparing to ball due to line
contact.
So most of Industrial fans, where radial load is high - cylindrical roller or
spherical roller bearing is used.
Apart from this, Selection between roller or ball bearing is also depends
on OEM(Original Equipment Manufacturer) System Design.

613. How is thermodynamics relevant for Mechanical

Engineering student?
It is very important for mechanical student .For mechanical student ,
during b.tech one has to study this subject in the first and second
year both. This subject contains the basic of other subject also .
We must have a conceptual knowledge of the thermodynamics to
study fluid dynamics also.

614.Cost C is a function of time T. C increases with T.

Represent it in a graph

162
 615. How are the wheels of a locamotive manufactured?
Forging

616.How are ball bearings made?

The manufacturing process for ball bearings can be broken down to four
components: the outer race, inner race, rolling balls and cage
formation. Both the inner and outer races are made using a
similar process. Starting with steel tubing, machine cutting tools
cut the tubing slightly larger than the race shape.

617. Which is the suitable material to make Coil Springs?

The most popular alloys include high-carbon (such as the music wire used
for guitar strings), oil-tempered low-carbon, chrome silicon,
chrome vanadium, and stainless steel. Other metals that are
sometimes used to make springs are beryllium copper alloy,
phosphor bronze, and titanium.

618.How is the fan relevant to thermodynamics?

The fan motor converts it to mechanical energy, the moving fan blades.
But it doesn't do convert electricity to motion at 100% efficiency.

163
 The wires in the fan motor have resistance, which creates some
heat. Thus, some of the electricity is turned into heat right away.

619.Which crystalline structure is responsible for hardness

in Steel?
The steel must be heated to a temperature where the iron phase changes
from ferrite into austenite, i.e. changes crystal structure from BCC
(body-centered cubic) to FCC (face-centered cubic). In austenitic
form, steel can dissolve a lot more carbon. Once the carbon has
been dissolved, the material is then quenched.

620. What is re-crystallization temperature?

Recrystallization temperature is a particular temperature point below the
melting point of a metal (or material). ... This is because the grains
at this temperature, make the metal behave in plastic manner,
allowing them to deform greatly for very less force application.

621. When you open a tap a little water trickles down. When
you open it more water gushes forth. What is the
change? Is it change in pressure, momentum, velocity?
Explain.
Momentum

622.How does the % carbon in mild steel influence the

strength?
carbon is an interstitial element which causes solid solution combining
with iron in steel. As a result it causes solid solution hardening in
steel. It increases strength and hardness of steel by this solid
solution formation. Increasing carbon content decreases ductility,
toughness and weldability. Hence according to the particular
applications of steels, optimum amount of carbon is required.

164
 623.What is the reason for low voltage in rural areas?
Poor wiring condition. Old wires and corrosion are two of the
common causes of low voltage. Another reason can be dirty
connections and weak insulation. Apart from that, if the
population increases the demand increases and this leaves an
impact on the distribution of voltage.

624. What are the common defects in a casting?

In die casting the most common defects are misruns and cold shuts.
These defects can be caused by cold dies, low metal temperature,
dirty metal, lack of venting, or too much lubricant. Other possible
defects are gas porosity, shrinkage porosity, hot tears, and flow
marks.

625.What is a pitot tube?

It is a flow measurement device used to measure fluid flow velocity. 

626. How do you determine the depth of a surface crack in

a casting?
Ultrasonic testing

627.When do you that a fluid is irrotational?

Irrotational flow is a flow in which each element of the moving
fluid undergoes no net rotation with respect to a chosen
coordinate axes from one instant to other. A well-known example
of irrotational motion is that of the carriages of the Ferris wheel
(giant wheel).

628. Whay is mecahnical machines ( IC Engines ) operate

with low efficiency when compared with electrical
machines ( Motors, Generators )?
Fundamentally because the energy exchange between the fuel and the

165
 moving parts is mediated by heat

629. What is the lowest possible temperature that you can

cool a fluid?
Absolute zero is the lowest limit of the
thermodynamic temperature scale, a state at which the enthalpy
and entropy of a cooled ideal gas reach their minimum value,
taken as zero kelvins. The fundamental particles of
nature have minimum vibrational motion.

630. For a given compression ratio which is more efficient -

Petrol Engine or Diesel Engine?
Otto cycle is more efficient than Diesel cycle for a given compression
ratio. 

631. For a wooden table how would I do a non-destructive

testing?
Sonic stress waves, ultrasonic stress waves, ultrasonics, and ultrasonic
pulse methods.

632.Compressor process - Is it adiabatic or isothermal?

Explain
Adiabatic. Isothermal compression requires heat transfer to the
surroundings to maintain constant temperature, lowering the
pressure of the system and thus lowering the resistance
to compression compared to the adiabatic compression 

633. Draw a component that can be manufactured using

the Lathe machine
N/A

634. What are the different types of Casting techniques?

166
Examples are Centrifugal casting, Extrusion, Forging, Full mold casting,
Investment casting, Permanent or Gravity Die casting, Plaster
mold casting, Sand Casting, Shell Mold casting. The method to be
used depends upon the nature of the products to be cast.

635. Where is cast iron used? How do you determine if cast

iron could be used?
It is used in making pipes, to carry suitable fluids.
It is used in making different machines.
It is used in making automotive parts.
It is used in making pots pans and utensils.
It is used in making anchor for ships.

636. What is the composition of High Speed Steel (HSS)?

18% tungsten, 4% Chromium, 1% Vanadium, 0.7% carbon and the rest, Iron.

637.Provide an example of a forged component

bulkheads, wing roots and spars, hinges, engine mounts, brackets,
beams, shafts, landing gear cylinders and struts, wheels, brake
carriers and discs and arresting hooks.

638. Provide the practical uses for Copper

As a result of its excellent electrical conductivity, copper's most
common use is in electrical equipment such as wiring and motors.
Because it corrodes slowly, copper is used in roofing, guttering,
and as rainspouts on buildings. It is also used in plumbing and in
cookware and cooking utensils.

639. What is a SCARA Robot?

SCARA robot is a manipulator with four degrees of freedom. This type
of robot has been developed to improve the speed and
repeatability ON PICK&PLACE TASKS from one location to

167
 another or to speed and improve the steps involved in assembly.

640. Draw the sketch of a shaft with some length and

diameter

641.Provide the name of a bearing manufacturer

Aisin Seiki

642. How is the strength of steel dependent on the

%carbon content?
carbon is an interstitial element which causes solid solution combining
with iron in steel. As a result it causes solid solution hardening in
steel. It increases strength and hardness of steel by this solid
solution formation. Increasing carbon content decreases ductility,
toughness and weldability. Hence according to the particular
applications of steels, optimum amount of carbon is required.

643. What is the difference between Drilling & Boring?

Drilling is a process for removing material from a workpiece in order to
168
 create a hole. Boring, on the other hand, is a process of enlarging
a hole that has already been made by another process (such
as drilling or casting). In short, boring is a secondary finishing
operation

644. Explain the differences between Fabrication &

Machining?
Fabrication means to build something without just assembling the
components. For example, in most of the automobile plants,
components are just assembled. ... Machining operation is a
subset of Fabrication operations. Machining refers to those
operations where material is being removed from parent
workpiece.

645. What is manufacturing? How is manufacturing

different from machining?
Manufacturing is the making of goods by hand or by machine that upon
completion the business sells to a customer. Items used
in manufacture may be raw materials or component parts of a
larger product. The manufacturing usually happens on a large-
scale production line of machinery and skilled labor.
In short, production has a vast area and it encompasses manufacturing;
while machining is one type of manufacturing processes.
Basically, production is a system (usually closed), manufacturing is
a group of processes, machining is a process, and turning, milling,
drilling, etc. are operations.

646. Which welding gives maximum strength - Lap or Butt

welding? Explain
For welding joint strength, a butt joint produces much stronger
attachment than a lap joint. The stronger attachment is
contributed by a larger volume of welded stainless steel 304 at

169
 the joint interfaces.

647. What are the differences between TIG & MIG welding?
The difference between the two is the way the arc is used. MIG (metal
inert gas) welding uses a feed wire that constantly moves
through the gun to create the spark, then melts to form
the weld. TIG (tungsten inert gas) welding uses long rods to fuse
two metals directly together.

648. How would you test the strength of a welding?

To prepare the sample, cut the tubing in half, and then flatten it.
To measure the strength of the weld, there is a calculation using
the total area of the weld by the strength it took to break that
weld. Consistency in the size of the weld or the tube does not
matter.

649. Draw the stress-strain diagram for any visco-elastic

material

170
 650. What is annealing?
In metallurgy and materials science, annealing is a heat treatment that
alters the physical and sometimes chemical properties of a
material to increase its ductility and reduce its hardness, making it
more workable.

651. What is the difference between Piercing and Blanking?

Blanking and piercing are shearing processes in which a punch and die are
used to modify webs. The tooling and processes are the
same between the two, only the terminology is different:
in blanking the punched out piece is used and called a blank;
in piercing the punched out piece is scrap.

652.How do you manufacture dye's?

Dyes are synthesized in a reactor, filtered, dried, and blended with other
additives to produce the final product. In general, organic
compounds such as naphthalene are reacted with an acid or an
alkali along with an intermediate (such as a nitrating or a
sulfonating compound) and a solvent to form a dye mixture.

653. What is a Draft angle? Explain its relevance

In engineering, draft is the amount of taper for molded or cast parts
perpendicular to the parting line. It can be measured in degrees
or mm/mm. Consider the fabrication of a hollow plastic box,
without lid. Once the plastic has hardened around the mold, the
mold must be removed. 

654. What is SWAT anlaysis?

There is no such analysis

655. What are the differences between Jigs & Fixtures?

171
 656. What is rivetting? How is it different from Welding?
A rivet is a permanent mechanical fastener. Before being installed, a rivet
consists of a smooth cylindrical shaft with a head on one end. The
end opposite to the head is called the tail.

657.What is the formula used for Gear design?

172
 658. What is a Wankel Engine?
The Wankel engine is a type of internal combustion engine using an
173
 eccentric rotary design to convert pressure into rotating motion.
All parts rotate in one direction, as opposed to the common
reciprocating piston engine, which has pistons instantly and
rapidly changing direction 180 degrees.

659. What is a thread chaser?

A thread restorer is a tool used to fix threads on nuts or bolts that have
become damaged. One type of thread restorer is a thread
restoring file. There are other types of thread restoring tools as
well.

660. What is a spring washer?

Spring washers, which have axial flexibility and are used to prevent
fastening or loosening due to vibrations. Locking washers, which
prevent fastening or loosening by preventing unscrewing rotation
of the fastening device; locking washers are usually also spring
washers.

661.For the manufacturing of a bottle come up with a

process plan
Plastic Water Bottle Manufacturing Process
The first stage in bottle manufacturing is stretch blow molding. The PET is
heated and placed in a mold, where it assumes the shape of a
long, thin tube (the process by which the plastic is forced into the
mold is called injection molding

662. Draw the stress-strain diagram for mild steel and glass

174
 663. What is Rapid Proto Typing (RPT)?
Rapid prototyping is a group of techniques used to quickly fabricate a
scale model of a physical part or assembly using three-
dimensional computer aided design data. Construction of the part
or assembly is usually done using 3D printing or "additive layer
manufacturing" technology.

664. What is the fuel used in an aircraft?

Jet fuel is a clear to straw-colored fuel, based on either an unleaded
kerosene (Jet A-1), or a naphtha-kerosene blend (Jet B). Similar to
diesel fuel, it can be used in either compression ignition engines
or turbine engines.

665. What are the differences between a Composite & an

alloy?

175
 666. Mention some uses of jigs
a jig is a type of tool used to control the location and/or motion of
another tool. A jig's primary purpose is to provide repeatability,
accuracy, and interchangeability in the manufacturing of
products. A device that does both functions (holding the work
and guiding a tool) is called a jig.

176
 667. How can we measure hardness of a material?
A hardness test is typically performed by pressing a specifically
dimensioned and loaded object (indenter) into the surface of
the material you are testing. The hardness is determined
by measuring the depth of indenter penetration or
by measuring the size of the impression left by an indenter.

668. Explain the die-casting process

Die casting is a metal casting process that is characterized by forcing
molten metal under high pressure into a mold cavity. The mold
cavity is created using two hardened tool steel dies which have
been machined into shape and work similarly to an injection mold
during the process.

669. Explain the differences between Hot Rolling & Cold

Rolling

177
 670. Explain the differences between 2 stroke and 4 stroke
petrol engines

178
 671. What is Broaching?
Broaching is a machining process that uses a toothed tool, called a
broach, to remove material. There are two main types of
broaching: linear and rotary. In linear broaching, which is the
more common process, the broach is run linearly against a surface
179
 of the

672.What are the differences between Power steering &

Mechanical steering?
Key Difference: Power steering is a system that helps in steering the
wheels by using some power of engine. Mechanical steering is
a steering system in which mechanical force is used
for steering. ... However, today most of the cars have power
steering systems.

673.Draw the conventional representation of a Screw

thread
Screw threads and conventional representations. ... The thread pitch is
the distance between corresponding points on adjacent threads.
Measurements must be taken parallel to the thread axis. The
major diameter or outside diameter is the diameter over the
crests of the thread, measured at right angles to the thread axis.

674. Why do heavy vehicles use Diesel engines?

Bulky automobiles such as trucks and cars require a huge amount of force
to run the vehicle at the slow speed. As almost everybody knows
that petrol burns faster than diesel, the diesel engine achieves a
higher torque at slow speed. So that's why are diesel engines
used in heavy vehicles.

675.What is Design of Experiment (DOE)?

The design of experiments is the design of any task that aims to describe
and explain the variation of information under conditions that are
hypothesized to reflect the variation.

676. What do you know about emission standards such as

E01, E02 etc?

180
Emission standards are the legal requirements governing air pollutants
released into the atmosphere. Emission standards set
quantitative limits on the permissible amount of specific air
pollutants that may be released from specific sources over
specific timeframes.

677.Which material is used for making shafts? Explain how

that material is suitable for making shafts
 The material used for ordinary shafts is mild steel. When high strength is
required, an alloy steel such as nickel, nickel-chromium
or chromium-vanadium steel is used.

678. What is a pressure sensitive alarm?

pressure sensitive alarm. The alarm uses a home-made pressure sensor,
which works as a variable capacitor using two copper-clad boards
and a piece of sponge in between them. ... These wires are used
for connecting the pressure sensor to the input of
the alarm circuit.

679. Explain the differences between a Petrol engine and a

Diesel engine?

181
 680. In an automobile what type of steering mechanism is
used?
Power steering and mechanical steering

681.What is a metal removal process? Provide some

examples
Material removal process is a type of manufacturing process in which the
final product is obtained by removing excess metal from the
stock. The best example of a machining process is generating a
cylindrical surface from a metal stock with the help of a lathe.

682. What are the differences between a machine tool and

a machine?
A machine is used to serve a particular purpose such as lifting heavy
objects, transporting. Eg:- Cranes, Elevators. A machine tool

182
 is a machine which is specifically designed to cut a metal into
desired shape in order to process.

683. In metal forming what type of operations can be

done?
Forming, metal forming, is the metalworking process of
fashioning metal parts and objects through mechanical
deformation; the workpiece is reshaped without adding or
removing material, and its mass remains unchanged.

684. What do you mean by the term "Lean

Manufacturing"?
Lean manufacturing, or lean production, is a production method derived
from Toyota's 1930 operating model "The Toyota Way".

685. What material can be made from a dye-casting

process?
die castings are made from non-ferrous metals, specifically zinc, copper,
aluminium, magnesium, lead, pewter, and tin-based alloys.
Depending on the type of metal being cast, a hot- or cold-
chamber machine is used.

686. What are the raw materials used for Foundry?

● Aluminum.
● Iron.
● Steel.
● Stainless steel.
● Gold.
● Silver.
● Copper.
● Magnesium.

183
 687. What are the Quality processes followed in Industry?
In manufacturing, quality control is a process that ensures customers
receive products free from defects and meet their needs. Some
common tools used to support quality control include:
Statistical process control (SPC) monitors and controls quality by
tracking production metrics.

688. What are the defects in Casting?

689. What is shot blasting?

Shot blasting is a method used to clean, strengthen (peen) or

184
 polish metal. Shot blasting is used in almost every industry
that uses metal, including aerospace, automotive,
construction, foundry, shipbuilding, rail, and many others.
There are two technologies used: wheel blasting or air
blasting.

690. What are the differences between IC Engines and EC

Engines?

691.Explain the working of a Thermal Power Plant?

In thermal power plants, the heat energy obtained from
combustion of solid fuel (mostly coal) is used to convert
water into steam, this steam is at high pressure and
temperature. This steam is used to rotate the turbine blade
turbine shaft is connected to the generator.

692. What is Otto cycle?

185
 An Otto cycle is an idealized thermodynamic cycle that describes
the functioning of a typical spark ignition piston engine. It
is the thermodynamic cycle most commonly found in
automobile engines.

693. What are the differences between a 2 stroke engine

and a 4 stroke engine?

186
 694. What is knocking in Petrol Engines?
Knocking in spark ignition internal combustion engines occurs
when combustion of some of the air/fuel mixture in the
cylinder does not result from propagation of the flame
front ignited by the spark plug, but one or more pockets of
air/fuel mixture explode outside the envelope of the
normal combustion front.

695. Which is more efficient 2 stroke or 4 stroke engines?

4 – stroke

696. What are the differences between 1st angle and 3rd
angle projections?

187
 697. Explain what is meant by Geometric Dimensioning &
Tolerance (GD & T)?
Geometric dimensioning and tolerance (GD&T) is a system for
defining and communicating engineering tolerances.
Tolerance specifications define the allowable variation for
the form and possibly the size of individual features, and
the allowable variation in orientation and location between
features.

698. What are the symbols used in GD & T?

188
 699. Explain the difference between Center Lathe and
Speed Lathe?

189
 700. What operations can be performed in a Lathe?

190
 701. What are the various processes to be followed in the
design of a product?

702.Explain the difference between ductility & brittleness?

191
 703.Categorize the following as to whether they are ductile
(or) brittle : Cast Iron, Steel, Aluminum
Brittle- cast iron
Ductile – Steel Aluminum

704. What is annealing?

In metallurgy and materials science, annealing is a heat treatment
that alters the physical and sometimes chemical properties
of a material to increase its ductility and reduce its
hardness, making it more workable.

705.What is carburizing?
Carburizing, carburizing, or carburization is a heat treatment
process in which iron or steel absorbs carbon while the
192
 metal is heated in the presence of a carbon-bearing
material, such as charcoal or carbon monoxide. The intent
is to make the metal harder.

706. What is stress? What is strain? What is Young's

modulus?
Stress is the ratio of applied force F to a cross section area -
defined as "force per unit area". Tensile stress - stress that
tends to stretch or lengthen the material - acts normal to
the stressed area. 
Strain. Strain is the response of a system to an applied stress.
When a material is loaded with a force, it produces a stress,
which then causes a material to deform. Engineering
strain is defined as the amount of deformation in the
direction of the applied force divided by the initial length
of the material.
Young's modulus, or the Young modulus, is a mechanical property
that measures the stiffness of a solid material. It defines
the relationship between stress and strain in a material in
the linear elasticity regime of a uniaxial deformation.

707.Explain the principle of a pump

Pump Working Principle, Types and Differences. A pump is a
mechanical device that is used to pick up water from low-
pressure level to high-pressure level. The pump changes
the energy flow from mechanical to the fluid. This can be
used in process operations, which needs a high hydraulic
force.

708. What is Bernoulli's equation?

In fluid dynamics, Bernoulli's principle states that an increase in the
speed of a fluid occurs simultaneously with a decrease in

193
 static pressure or a decrease in the fluid's potential
energy. 

709. Explain what is meant by surface roughness? How is it

measured?
Surface roughness often shortened to roughness, is a component
of surface texture. It is quantified by the deviations in the
direction of the normal vector of a real surface from its
ideal form. If these deviations are large, the surface is
rough; if they are small, the surface is smooth.

710. What are the differences between a thermocouple and

thermostat?

711. What are G codes and M codes with respect to CNC

machines?
G-code deals with the geometry of the hardware, for example,
straight cutting developments, penetrating tasks and
determining the units of estimation. While M-codes deals
with the configuration of the machine tools Such as On/off
commands and bringing back the machine to the origin or
the cutting point.

712. What is the difference between Shaping and Planing?

194
 713. Explain what is meant by Least Count of an instrument?
The smallest value that can be measured by the
measuring instrument is called its least count. Measured
values are good only up to this value. The least count error is
the error associated with the resolution of the instrument.

714. What do you know about the tumbler mechanism?

Tumbler gear mechanism is used to change the direction of lead
screw and feed rod in lathe machines. By
Engaging tumbler gear, the carriage can be moved
automatically from tailstock end to headstock.

715. What is tolerance?

Toleration is the allowing, permitting, or acceptance of an action,
idea, object, or person, which one dislikes or disagrees
with.

195
 716. What is fatigue failure?
In materials science, fatigue is the weakening of a material caused
by cyclic loading those results in progressive and localized
structural damage and the growth of cracks.

717. What is bending moment? What is the significance of

the bending moment in shaft design?
A bending moment is the reaction induced in a structural element
when an external force or moment is applied to the
element causing the element to bend. The most common
or simplest structural element subjected to bending
moments is the beam. 

718. What is the 0th law of thermodynamics?

The zeroth law of thermodynamics states that if two
thermodynamic systems are each in thermal equilibrium
with a third one, then they are in thermal equilibrium with
each other. 

719. What is milling? What is up milling and down milling?

Milling is the process of machining using rotary cutters to remove
material by advancing a cutter into a work piece. This may
be done varying direction on one or several axes, cutter
head speed, and pressure. 

720.Explain what is meant by drawing?

Drawing is a metalworking process, which uses tensile forces to
stretch metal or glass. As the metal is drawn (pulled), it
stretches thinner, into a desired shape and thickness.
Drawing is classified in two types: sheet metal drawing and
wire, bar, and tube drawing.

196
 721. How will you manufacture a steel paperweight? What
are all the processes involved?
Casting, Milling, Surface Finishing

722. What are the differences between drilling, boring and

reaming?

723. What are the components of an engine ( either petrol

engine or diesel engine )
● Spark plugs
● Valves
● Piston
● Piston rings
● Connecting rod
● Crankshaft
● Sump

724.Explain the manufacturing processes involved in the

manufacture of Glass?
Glass Manufacturing Process # 1. Collection of Raw
Materials:
Depending upon the type of glass to be manufactured,
suitable raw materials are collected. Table 14-1 shows the
raw materials required for each type of glass.

197
 In addition to the raw materials, the cullet and
decolourisers are also added for each type of glass.
ADVERTISEMENTS:
The cullet indicates waste glass or pieces of broken glass.
They increase the fusibility of glass and prevent loss of
alkali by volatisation during the reaction in forming new
glass. They also reduce the cost.
The raw materials generally contain traces of the iron
compounds. The ferrous oxide imparts a green colour to
glass and ferric oxide imparts a very light yellow tint. To
avoid such effects, the decolourisers are added. The usual
substances used as decolourisers are antimony oxide
(Sb2O3), arsenic oxide (AS2O3), cobalt oxide (CoO),
manganese dioxide (MnO2) and nickel oxide (NiO).
Glass Manufacturing Process # 2. Preparation of Batch:
The raw materials, cullet and decolouriser are finely
powdered in grinding machines. These materials are
accurately weighed in correct proportions before they are
mixed together. The mixing of these materials is carried
out in mixing machines until a uniform mixture is obtained.
Such a uniform mixture is known as the batch or frit and it
is taken for further process of melting in a furnace.
Glass Manufacturing Process # 3. Melting in Furnace:
ADVERTISEMENTS:
198
 The batch is melted either in a pot furnace or in a tank
furnace. The heating is continued until the evolution of
carbon dioxide, oxygen, sulphur dioxide and other gases
stops.
(i) Pot Furnace:
In this furnace, the pots are adopted as units. A typical
glass melting pot is shown in fig. 14-1.

A pot is a vessel made of fire-clay. This process resembles

the crucible steel process. These pots are placed in
specially prepared holes in the furnace. The charging and
collecting doors are kept projecting outside so that raw
materials may be added and molten glass may be taken out
conveniently.
ADVERTISEMENTS:
The pots are filled with raw materials. The furnace is
heated by means of producer gas. When the mass has
melted down, it is removed from the pot and it is taken for
the next operation of fabrication. The melting of glass by
pot furnace is an intermittent process. It is used to melt
small quantities of glass at a time or to prepare special
types of glass.
199
 (ii) Tank Furnace:
This furnace resembles the reverberatory furnace adopted
for puddling of the wrought-iron. Fig. 14-2 shows the
section of a tank furnace adopted for the melting of glass.
It is constructed with reinforced masonry. The roof is given
special shape to deflect the flames of heated gas.
ADVERTISEMENTS:
The ports are provided for the entry of preheated
producer gas. The doors are provided for charging and for
taking out the molten glass. A bridge separates the tank
into two unequal compartments.

The batch is heated in large compartment and it contains

somewhat impure glass. It flows through opening of
bridge into small compartment. The gall or floating
impurities are collected at the top of large compartment.
The refractory lining is provided to the interior surface of
tank.
The tank is filled with raw materials. The furnace is heated

200
 by allowing producer gas through ports. The charging of
raw materials and taking out of molten mass are
simultaneous. This is a continuous process and it is
adopted to melt large quantities of glass at a time.
Glass Manufacturing Process # 4. Fabrication:
ADVERTISEMENTS:
The molten glass is given suitable shape or form in this
stage. It can either be done by hand or by machine. The
hand fabrication is adopted for small scale production and
machine fabrication is adopted for large scale production.
Following are the different ways of fabrication:
(i) Blowing
(ii) Casting
(iii) Drawing
(iv) Pressing
(v) Rolling
(vi) Spinning.
(i) Blowing:
For this purpose, a blow-pipe is used. Its diameter is about
12 mm and its length is about 1.80 m. One end of the blow-
pipe is dipped in the molten mass of glass and a lump of
about 50 N weight is taken out. This lump of glass will then
lengthen to some extent by its own weight.
The operator then blows vigorously from other end of
blow pipe. It can also be done with the help of an air
compressor. This blowing causes the molten mass to
assume the shape of a cylinder. It is then heated for few
seconds and is blown again.
The blowing and heating are continued till the cylinder of
required size is formed. It is then placed on an iron plate
and it is disconnected from blow pipe. The cylinder is then
cut vertically by a diamond. It falls into a thin plate by

201
 gravity.
(ii) Casting:
The molten glass is poured in moulds and it is allowed to
cool down slowly. The large pieces of glass of simple
design can be prepared by this method. It is also adopted
to prepare mirrors, lenses, etc.
(iii) Drawing:
This process consists in simply pulling the molten glass
either by hand or by mechanical equipment. An iron bar is
dipped sideways in the molten mass of glass. It is lifted up
horizontally and in doing so, it catches up a sheet of
molten glass. This sheet is then allowed to pass over a
large rotating roller. The roller helps the molten glass to
spread in the form of a thin sheet.
(iv) Pressing:
In this process, the molten glass is pressed into moulds.
The pressure may either be applied by hand or by
mechanical means. This process is adopted for ornamental
articles, hollow glass articles etc.
(v) Rolling:
There are two methods of rolling. In one method, the
molten mass of glass is passed between heavy iron rollers
and flat glass plate of uniform thickness is obtained. In
another method, the molten mass of glass is poured on a
flat iron casting table and it is then turned flat with the aid
of a heavy iron roller.
(vi) Spinning:
In this process, the molten glass is spun at high speed by a
machine to form very fine glass fibres. This glass has tensile
strength equal to that of mild steel. It does not fade, decay
or shrink. It is not attacked by acids, fire and vermins. It is
very soft and flexible. It is used for providing insulation

202
 against heat, electricity and sound.
Glass Manufacturing Process # 5. Annealing:
The glass articles, after being manufactured, are to be
cooled down slowly and gradually. This process of slow
and homogeneous cooling of glass articles is known as the
annealing of glass.
The annealing of glass is a very important process. If glass
articles are allowed to cool down rapidly, the superficial
layer of glass cools down first as glass is a bad conductor of
heat. The interior portion remains comparatively hot and it
is therefore in a state of strain. Hence, such glass articles
break to pieces under very slight shocks or disturbances.
Following are the two methods of annealing:
(i) Flue treatment
(ii) Oven treatment.
(i) Flue Treatment:
In this method, a long flue is provided and it is constructed
in such a way that there is gradual decrease in temperature
from one end of flue to the other. The red-hot articles of
glass are allowed to enter at the hot end of flue and they
are slowly moved on travelling bands. They become cool
when they reach the cool end of flue. This method is useful
for large scale production.
(ii) Oven Treatment:
In this method, the red-hot glass articles are placed in
ovens in which arrangement is made to control the
temperature. After articles are placed in the ovens, the
temperature is slowly brought down. This method is useful
for small scale production.

725.What are the different types of welding?

 MIG - Gas Metal Arc Welding (GMAW)

203
  TIG - Gas Tungsten Arc Welding (GTAW)
 Stick - Shielded Metal Arc Welding (SMAW)
 Flux-Cored Arc Welding (FCAW)
 Energy Beam Welding (EBW)
 Atomic Hydrogen Welding (AHW)
 Gas Tungsten-Arc Welding
 Plasma Arc Welding

726.What are the different types of weld joints?

Single butt joint, double butt joint, lap joint etc.

727. Explain the following welding processes : Gas welding

and Plasma Arc welding
Gas welding : Oxy-fuel welding (commonly
called oxyacetylene welding, oxy welding, or gas
welding in the U.S.) and oxy-fuel cutting are processes that
use fuel gases (or liquid fuels such as gasoline) and oxygen
to weld or cut metals. French engineers Edmond Fouché
and Charles Picard became the first to develop oxygen-
acetylene welding in 1903.Pure oxygen, instead of air, is
used to increase the flame temperature to allow localized
melting of the workpiece material (e.g. steel) in a room
environment. A common propane/air flame burns at about
2,250 K (1,980 °C; 3,590 °F), a propane/oxygen flame burns
at about 2,526 K (2,253 °C; 4,087 °F),] an oxyhydrogen flame
burns at 3,073 K (2,800 °C; 5,072 °F) and an
acetylene/oxygen flame burns at about 3,773 K (3,500 °C;
6,332 °F).
Plasma Arc welding : Plasma arc welding (PAW) is
an arc welding process similar to gas tungsten arc
welding (GTAW). The electric arc is formed between
an electrode (which is usually but not always made
of sintered tungsten) and the workpiece. The key

204
 difference from GTAW is that in PAW, by positioning the
electrode within the body of the torch, the plasma arc can
be separated from the shielding gas envelope.
The plasma is then forced through a fine-bore copper
nozzle which constricts the arc and the plasma exits
the orifice at high velocities (approaching the speed of
sound) and a temperature approaching 28,000 °C
(50,000 °F) or higher.

728.What are the defects that can occur in Welding?

729.Explain the differences between TIG welding and MIG

welding?

205
 730.What is run out?
Run-out or runout is an inaccuracy of
rotating mechanical systems, specifically that the tool or
shaft does not rotate exactly in line with the main axis.

731. What are the differences between turning and phasing?

The primary difference is that
in Facing/ Turning operations, your work piece that you
need to machine is going to rotate, while in a milling
operation, your tool is going to rotate. Turning is usually
defined for cylindrical workpieces. This is used to reduce
the diameter of a workpiece.

732. What are the various metal joining processes?

206
 733.What is the differences between Brazing and Soldering?
The basic and main difference between
soldering and brazing is that soldering is used to make a
electrically strong joint between metals which can
withstand with all electric loads and brazing is used to
make a mechanical strong joint which can withstand with
all mechanic loads and stresses.

734.For welding of disimilar metals what kind of electrode is

used?
In the case of Inconel to mild or low-alloy steel the
Inconel base electrode would be used. The same situation
applies also to the welding of Inconel or Monel to stainless
steels. Here the Inconel or Monel type electrode is used.

735.What is punching operation?

Punching is a forming process that uses a punch press to
force a tool, called a punch, through the workpiece to
create a hole via shearing.

207
 736.What is Drawing? What are the differences between
Rolling & Drawing?
Because of high temperatures during rolling, the cooling
process typically involves surface oxidation.
Cold rolling increases the yield strength of the metal stock,
producing a denser, more compact end product.
Drawing is classified as a cold working process because the
wire is typically drawn at room temperature.

737.What is the manufacturing process used for Rs 1 coin?

Punching

738.What is the manufacturing process used for bottle

shapes in steel?
Casting

739.What is circularity? What is cylindricity?

Cylindricity is a 3-Dimensional tolerance that controls the
overall form of a cylindrical feature to ensure that it is
round enough and straight enough along its axis.
Cylindricity essentially forms a perfect cylindrical boundary
around the object that the entire 3-Dimensional part must
lie in.

740. What is the mechanism used in CNC machine to turn

rotary motion to linear motion?
Slider-crank mechanism

741. What is the Air Fuel ratio maintained for Petrol and
Diesel engines?
 Petrol – 14.7:1
 Diesel – 18:1

208
 742.What is the purpose of a spark plug in a petrol engine?
To initiate the ignition process

743.Explain what is meant by turbulence?

Turbulence is an irregular motion of the air resulting
from eddies and vertical currents. It may be as insignificant
as a few annoying bumps or severe enough to
momentarily throw an airplane out of control or to cause
structural damage. Turbulence is associated with fronts,
wind shear, thunderstorms, etc.

744. What is the difference between stream lined flow and

turbulent flow?
Streamline flow is when the flow is parallel to the
streamline drawn. In turbulent flow, the flow does not
follow streamline.

745.What is CRDI principle?

The working principle of Common Rail Direct Injection
The pump compresses the fuel at the pressures of about
1,000 bar or about 15,000 psi. It, then, supplies the
pressurized fuel via a high-pressure pipe to the inlet of the
fuel rail.

746. What is the purpose of a turbo-charger?

Uses exhaust gases and send compressed air to the intake
manifold.

747.Explain the basic differences between a turbine and a

compressor?
Turbine extract energy by decreasing the pressure,
while compressor increase fluid pressure.
209
 748. What are the differences between Orthographic &
Isometric projections?
Orthographic Projection is used for making the
projects but Isometric Projection is used to have better
understanding of the object. Orthographic drawings are
typically two dimensional views of an object.
An isometric drawing is meant to depict a 3D image of an
object in what appears to be a perspective view.

749. What is meant by repeatability and accuracy of a

measuring instrument?
Accuracy: The maximum deviation of a measurement from
a known standard or true value. Repeatability: The
maximum deviation between measurements under the
same conditions and with the same measuring instrument.
This also refers to how stable the measurement will be
over time.

750.What is the difference between accuracy and precision

of a measuring instrument?
Accuracy describes 'close to true
value;' Precision describes 'repeatability. ' Accuracy in
measurement describes how closely
the measurement from your system matches the actual or
true measurement of the thing being measured. It is
the difference between the observed average
of measurements.

751. What is the difference between hot rolling and cold

rolling?
It's important to note that the main difference
between hot rolled and cold rolled steel is one of process.
210
 “Hot rolling” refers to processing done with heat. “Cold
rolling” refers to processes done at or near room
temperature.

752.What is the difference between Planing & Shaping?

The main difference between these two processes is that
in shaping the tool reciprocates across the stationary
workpiece. Planing motion is the opposite of shaping.
Both planing and shaping are rapidly being replaced by
milling. The mechanism used for this process is known as a
planer.

753.What is scavenging?
In an internal combustion engine, scavenging is the
process of replacing the exhaust gas in a cylinder with the
fresh air/fuel mixture (or fresh air, in the case of direct-
injection engines) for the next cycle. Scavenging is equally
important for both two-stroke and four-stroke engines.

754.State Hooke's law?

Hooke's law is a law of physics that states that
the force (F) needed to extend or compress a spring by
some distance (x) scales linearly with respect to that
distance where k is a constant factor characteristic of the
spring (i.e., its stiffness), and x is small compared to the
total possible deformation of the spring. 

755.What are the operations that can be done in a shaping

machine?
Horizontal cutting. Vertical cutting. Inclined cutting.
Irregular cutting.

756.What is Gear Hobbing?

211
 Hobbing is a machining process for gear cutting, cutting
splines, and cutting sprockets on a hobbing machine,
which is a special type of milling machine. The teeth or
splines of the gear are progressively cut into the material
(a flat, cylindrical piece of metal) by a series of cuts made
by a cutting tool called a hob.

757.What is the basic difference between a Lathe and a

milling machine?
Lathes and milling machines are both used for cutting raw
material, but they have very different ways of doing
so. Lathes spin the material, whereas a milling
machine uses a spinning tool for various cutting
operations.

758.How can we test the hardness of a material?

A hardness test is typically performed by pressing a
specifically dimensioned and loaded object (indenter)
into the surface of the material you are testing.
The hardness is determined by measuring the depth of
indenter penetration or by measuring the size of the
impression left by an indenter.

759.What are the components of a pump?

Pump components and seals. The main components in a
pump are the casing, impeller, backing
plate, shaft and shaft seal, and the motor adapter.

760. What is the purpose of an impeller in a pump?

An impeller is a rotating component of a
centrifugal pump which transfers energy from the motor
that drives the pump to the fluid being pumped by

212
 accelerating the fluid outwards from the center of
rotation.

761. What is Anti lock braking system(ABS)?

An anti-lock braking system (ABS) is a safety anti-skid
braking system used on aircraft and on land vehicles, such
as cars, motorcycles, trucks, and buses. ABS operates by
preventing the wheels from locking up during braking,
thereby maintaining tractive contact with the road surface.

762.What are the factors that influence the efficiency of a

pump?
Centrifugal pumps, engineered for operational
flexibility, efficiency and durability, meet
the pumping needs of many oil and gas applications.
These pumps operate efficiently in high-volume, low-
output pressure conditions. The following
main factors affect the performance of a centrifugal pump:
Working Fluid Viscosity.

763.What is Bernoulli's equation?

P + ½ ρ v2 +ρ g h = constant.

764. What are the various defects that could occur in a

Casting process?
  gas porosity, shrinkage, mold material, pouring metal, and
metallurgical Casting defects. Some casting defects can be
repaired while some are tolerated.

765.What is the difference between petrol and diesel

engines?
The main difference between diesel and petrol engines is

213
 that petrol engines use spark plugs to ignite the air-fuel
mixture, while diesel engines rely solely on heavily
compressed air. In petrol engines, the compression ratio is
generally much lower, because they rely more on the spark
plug to begin the power phase.

766. What is an external combustion engine?

An external combustion engine (EC engine) is a
heat engine where a working fluid, contained internally, is
heated by combustion in an external source, through
the engine wall or a heat exchanger. The fluid then, by
expanding and acting on the mechanism of the engine,
produces motion and usable work.

767.What will happen if you replace the injector with the

spark plug?
An engine was converted to direct injection of
natural gas using spark plug fuel injector which
combines fuel injector and spark plug for easy conversion.
The effect of injection timing on the performance and
combustion in a 0.507L single-cylinder engine fuelled with
natural gas substitute, methane was investigated.

768. To design an engine what parameters do you choose?

Basic design and performance parameters in internal
combustion engines include compression ratio, swept
volume, clearance volume, power output, indicated power,
thermal efficiency, indicated mean effective pressure,
brake mean effective pressure, specific fuel consumption,
and more.

769. What is the calorific value of a fuel?

214
 Fuel Calorific Values. The calorific value of a fuel is the
quantity of heat produced by its combustion – at constant
pressure and under “normal” (standard) conditions (i.e. to
0oC and under a pressure of 1,013 mbar).

770.Which has a higher calorific value? Petrol or diesel.

Petrol

771. What is flexible manufacturing system?

A flexible manufacturing system (FMS) is a manufacturing
system in which there is some amount of flexibility that
allows the system to react in case of changes, whether
predicted or unpredicted. This flexibility is generally
considered to fall into two categories, which both contain
numerous subcategories.

772. What are the different types of cutting tools?

Lathe. If you have ever wondered how to turn stairway
posts, a lathe is the answer.
Drill Press. The drill press bores precision holes, reams
openings and cuts threads.
Milling Machine.
Grinder.
Chop Saw.
Welders.
Handheld Rotary Tools.

773.What is Six Sigma?

Six Sigma (6σ) is a set of techniques and tools for process
improvement. ... A six sigma process is one in which
99.99966% of all opportunities to produce some feature of
a part are statistically expected to be free of defects.

215
 774.What is the need for Six Sigma?
One of the reasons why implementation of Six Sigma is
important is that it helps in reducing defects. Using Six
Sigma techniques, employees are able to identify problem
areas as well as recurring issues that affect the overall
quality expectation of a service or product from a
customer's viewpoint.

775.What is Stefan-Boltzman law?

Stefan-Boltzmann law. Stefan-Boltzmann law, statement
that the total radiant heat power emitted from a
surface is proportional to the fourth power of its absolute
temperature. The law applies only to blackbodies,
theoretical surfaces that absorb all incident heat radiation.

776.A bottle of water is kept and the temperature is taken

initially and after 4 hours. Is it possible to determine the
temperature of the surrounding?
Yes

777. What is the difference between a passenger aircraft and

cargo aircraft?
The main difference between cargo and passenger airline
pilots is that cargo pilots mostly fly at night, which means
that they have to operate outside of their normal circadian
rhythm and sometimes it could be quite challenging to
manage fatigue.

778.What is vibration? How do you measure vibration?

Vibration is a mechanical phenomenon whereby
oscillations occur about an equilibrium point. The word

216
 comes from Latin vibrationem ("shaking, brandishing").
The oscillations may be periodic, such as the motion of a
pendulum—or random, such as the movement of a tire on
a gravel road.
Vibration is most commonly measured using a ceramic
piezoelectric sensor or accelerometer. An accelerometer is
a sensor that measures the dynamic acceleration of a
physical device as a voltage.

779.How would you design a radiator?

Not very sure

780. What is the difference between a machining center

and a milling machine?
Milling machine is usually considered a manual milling
machine. Where the movement of the machine
is controlled by the operator by moving wheels and levers.
CNC machine is a machine that is controlled via computer.
Machining center is a CNC machine that has an added
benefit of an automatic tool changer.

781. What is line balancing?

A production line is said to be in balance when every
worker's task takes the same amount of time. Line
balancing is a manufacturing-engineering function in which
whole collection of production-line tasks are divided into
equal portions. Well-balanced lines avoid labour idealness
and improve productivity.

782.What is liquefaction?
Liquefaction takes place when loosely packed, water-
logged sediments at or near the ground surface lose their

217
 strength in response to strong ground shaking.

783.What is aerofoil?
a structure with curved surfaces designed to give the most
favourable ratio of lift to drag in flight, used as the basic
form of the wings, fins, and tailplanes of most aircraft.

784. What is stall speed ( of a glider )?

The new stalling speed is approximately 57 knots (square
root of √ 300 + 40 = 57). The heavy glider can fly faster than
the light glider while maintaining the same glide ratio as
the light glider.

785.What is co-efficient of drag?

In fluid dynamics, the drag coefficient is a dimensionless
quantity that is used to quantify the drag or resistance of
an object in a fluid environment, such as air or water. It is
used in the drag equation in which a lower drag coefficient
indicates the object will have less aerodynamic or
hydrodynamic drag.

786. What are the methods to improve the lift ( of an

aircraft )?
There are several devices that can be used on an aircraft
wing to increase its lift. We all know them as leading and
trailing edge flaps. Other techniques are also used
to increase the angle of attack (coefficient lift): vortex
generators, wing fences and discontinuous leading edges.

787.What are the 3 laws of thermodynamics?

The three laws of thermodynamics define physical
quantities that characterize thermodynamic systems at

218
 thermodynamic equilibrium. The laws describe how these
quantities behave under various circumstances, and
preclude the possibility of certain phenomena.

788. How would you explain a cutting tool?

With the help of the tools nomenclature

789. What is evaporative cooling?

An evaporative cooler is a device that cools air through the
evaporation of water. Evaporative cooling differs from
typical air conditioning systems, which use vapor-
compression or absorption refrigeration cycles.

790. What is Carnot's cycle? Why is it not practically

feasible?
Carnot cycle is an ideal reversible closed
thermodynamic cycle in which the working substance goes
through the four successive operations of isothermal
expansion to a desired point, adiabatic expansion to a
desired point, isothermal compression, and adiabatic
compression back to its initial state.

791. Explain the terms entropy & enthalpy

The entropy of an object is a measure of the amount of
energy which is unavailable to do work. Entropy is also a
measure of the number of possible arrangements the
atoms in a system can have. In this sense, entropy is a
measure of uncertainty or randomness.
When a substance changes at constant
pressure, enthalpy tells how much heat and work was
added or removed from the substance. Enthalpy is similar
to energy, but not the same. When a substance grows or

219
 shrinks, energy is used up or released.

792.What are the 3 Newton's laws of physics?

793.How would you design a brake system for a car?

Brake pedal is designed to withstand the maximum load of
2000N with the pedal ratio of 6:1.According to this law
when the pressure is applied on a fluid will travel equally in
all the directions hence the uniform braking action is
applied on all four wheels.

794. What is annealing?

In metallurgy and materials science, annealing is a heat
treatment that alters the physical and sometimes chemical
properties of a material to increase its ductility and reduce
its hardness, making it more workable.

795.What is resonance?
Resonance, An object free to vibrate tends to do so at a
specific rate called the object's natural, or resonant,
frequency.Such an object will vibrate strongly when it is
subjected to vibrations or regular impulses at a frequency
equal to or very close to its natural frequency. This
phenomenon is called resonance.

796. What is chamber of an aerofoil?

Camber is defined as the convexity of the curve of
an aerofoil from the leading edge to the trailing edge.

797.How does an aircraft work?

A plane's engines are designed to move it forward at high
speed. That makes air flow rapidly over the wings, which

220
 throw the air down toward the ground, generating an
upward force called lift that overcomes the plane's weight
and holds it in the sky. ... The wings force the air downward
and that pushes the plane upward.

798. What turbine is used in an aircraft?

As the jets of gas shoot backward, the engine and
the aircraft are thrust forward. As the hot air is going to
the nozzle, it passes through another group of blades
called the turbine. The turbine is attached to the same
shaft as the compressor. Spinning the turbine causes the
compressor to spin.

799. Why does the helicopter lifts straight away where as

an aircraft runs in the runway and then lifts?
Helicopters also make air move over airfoils to generate
lift, but instead of having their airfoils in a single fixed
wing, they have them built into their rotor blades, which
spin around at high speed (roughly 500 RPM, revolutions
per minute). The rotors are like thin wings, "running" on
the spot, generating a massive downdraft of air that blows
the helicopter upward. With skillful piloting, a helicopter
can take off or land vertically, hover or spin on the spot, or
drift gently in any direction—and you can't do any of that
in a conventional plane.

800. What are the differences between a passenger

aircraft and a cargo aircraft?
The main difference between cargo and passenger
airline pilots is that cargo pilots mostly fly at night, which
means that they have to operate outside of their normal
circadian rhythm and sometimes it could be quite

221
 challenging to manage fatigue.

801.What are the 7 ways to improve productivity through

lean manufacturing?

802. What is PERT analysis?

PERT Analysis. Program Evaluation and Review Technique
(PERT) is a method used to examine the tasked that are in
a schedule and determine a variation of the Critical Path
Method (CPM). It analyzes the time required to complete
each task and its associated dependencies to determine
the minimum time to complete a project 

803. What is the difference between constant mesh and

synchro mesh gear boxes?

804. Draw the iron carbon diagram of steel

222
 805. How would you design an aircraft?
By performing the following tasks
● Wing Design.
● Tail Design.
● Fuselage Design.
● Propulsion System.
● Landing Gear.
● Equipment/Subsystems.
● Integration.
● Wing Tunnel Testing.

806. What is non-sensitivity?

223
 nonsensitive. : not sensitive,not requiring special
protection oil production on nonsensitive public land

807. How did Six Sigma derive its name?

Six Sigma is a disciplined, statistical-based, data-driven
approach and continuous improvement methodology for
eliminating defects in a product, process or service. ...
Hundreds of companies around the world have adopted
Six Sigma as a way of doing business.

808. What are the different types of turbines that you are
aware of?
There are 3 main types of impulse turbine in use: the
Pelton, the Turgo, and the Crossflow turbine.

809. When you weld 2 metals the properties of the metals

change. It is called stress relieving. How would you
make up for it? (
By performing Heat Treatment

810.What is the critical speed of shafts?

Critical or whirling or whipping speed is the speed at which
the shaft tends to vibrate violently in transverse direction.
The eccentricity of the C.G of the rotating masses from the
axis of rotation of the shaft.

811. Explain mohr's circle? What does the radius indicate?

Mohr's circle is often used in calculations relating to
mechanical engineering for materials' strength,
geotechnical engineering for strength of soils, and
structural engineering for strength of built structures. It is
also used for calculating stresses in many planes by

224
 reducing them to vertical and horizontal components.
These are called principal planes in which principal stresses
are calculated; Mohr's circle can also be used to find the
principal planes and the principal stresses in a graphical
representation.

812. What is Fast Fourier Trandform (FFT)?

A fast Fourier transform (FFT) is an algorithm that
computes the discrete Fourier transform (DFT) of a
sequence, or its inverse (IDFT). Fourier analysis converts a
signal from its original domain (often time or space) to a
representation in the frequency domain and vice versa.

813. What is the example of application in vibration?

applications of vibrations include ultrasonic probes, both
for medical application and for nondestructive testing.

814.What are the types of welding?

225
 815. What are the types of casting? Explain each casting?

816.How does an induction motor work?

The motor which works on the principle of
electromagnetic induction is known as the induction
motor. The term excitation means the process of inducing
the magnetic field on the parts of the motor. When the
three phase supply is given to the stator, the rotating
magnetic field produced on it.

226
227
 ABOUT THE AUTHOR

Mrs. Tanuja P.T is a Training and Development professional with 10

plus years of work experience at HSBC, First American, Inter title and
Vibgyor High Schools. She lives in Bangalore, with her husband and 2
children.
She can reached at onehourtraining@gmail.com

228