BASICS OF

MECHANICAL
ENGINEERING
FOR SECOND SEMESTER
MECHANICAL ENGINEERING
& ALLIED COURSES

( REGULATION – 2023 )

WITH TWO MARKS

QUESTIONS & ANSWERS

N. IYANARAPPAN, M.E., M.I.S.T.E.

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(BASICS OF MECHANICAL ENGINEERING)
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 PREFACE

This book on Basic of Mechanical Engineering has

been written to cover the latest revised syllabus for the
Polytechnic college students of Second Semester Mechanical
Engineering & Allied Courses.

All the topics in this book are written in simple and

constructive manner with suitable examples and sketches.
I assure that the review questions added at the end of each Unit

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will be more helpful to the students while preparing for the
examination.
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I acknowledge my gratitude with thanks to M/s. KAL

Pathippagam for their kind encouragement to bring out this
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book in time. The author would be very glad and thankful to

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receive any comments and constructive suggestions for the

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improvement of this book.

N. IYANARAPPAN
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(iyanarvlr1976@[Link])
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All the best...

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 Contents

Unit Topic Page No.

Roles and Responsibilities of

Unit – I. 1.1 – 1.9
Mechanical Engineer

Engineering Materials,
Unit – II. 2.1 – 2.27
Metal Forming and Joining

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Fundamentals of
Unit – III. 3.1 – 3.13
Machine Tools
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Power Transmission Drives

Unit – IV. 4.1 – 4.18
and Lubrication
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Fundamentals of
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Unit – V. 5.1 – 5.21

Heat Power Engineering
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2 Marks Questions and Answers

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Model Question Papers

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 ME232120 BASICS OF MECHANICAL L T P C
Theory ENGINEERING 3 0 0 3

Unit – I ROLES AND RESPONSIBILITIES OF MECHANICAL ENGINEER

Introduction to Mechanical Engineering – Who is a Mechanical Engineer? – Job
Description – Roles and Responsibilities – Scope and Opportunities – Mechanical
Engineering – Manufacturing – Automobile – Power Generation – Maintenance – 9
Service – Design – Quality – Materials Management – Logistics.

Unit – II ENGINEERNG MATERIALS, METAL FORMING AND JOINING

Engineering Materials : Importance of Materials – Types – Properties –
Mechanical, Thermal, Electrical, Magnetic, Chemical – Usages – Applications.

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Metal Forming : Definition – Types – Hot and Cold working – Hot working –

A
Description and working of drop hammer – Rolling – Roll forging – Extrusion – 9
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Cold working – Description and working of Mechanical press– Wire drawing
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Metal Joining : Types of Joints – Definitions and Applications – Temporary and

Permanent – Examples.
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Unit – III FUNDAMENTALS OF MACHINE TOOLS

Machine Tools – Introduction
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Lathe : Principle of Lathe – Description and function of Lathe

Drilling Machine : Principle of Drilling – Types – Upright Drilling (Description
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and Function only)

9
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Milling Machine : Principle of Milling – Horizontal Milling Machine – Vertical

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milling machine (Description and Function only)

CNC : Introduction to CNC and its applications

Unit – IV POWER TRANSMISSION DRIVES AND LUBRICATION

Power Transmission Drives : Belt drive – Types – Flat, V Belt & Circular or Rope
Drive – Applications – Applications of chain drive – Gear drives – Types of gear
drives – spur gear drive – Helical gear drive – Bevel gear drive – Worm and Worm
wheel drive – Rack and pinion drive – Cam Drive – Descriptions.
9
Lubrication : Lubricants – Types – Solid, Semi Solid, Liquid – Properties of
lubricants – Purpose of lubrication – Methods of lubrication – Ring Oiler
Lubrication, Drip feed Lubrication and Grease Cup Lubrication.
Unit – V FUNDAMENTALS OF HEAT POWER ENGINEERING
Thermodynamics : Definition – Heat – Modes of heat transfer – conduction,
convection and radiation (Definition only)
IC Engines : Classification of IC Engines – Working of Four stroke Petrol Engine
– Diesel Engine –Introduction to Battery Electrical Vehicles (BEV) 9
Power Plants : Power Plants – Introduction to Steam Power plant – Introduction
to Nuclear Power plant – Introduction to Solar power plant (PV only) –
Introduction to Windmill – Horizontal axis and vertical axis wind mill

TOTAL HOURS 45

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ASSESSMENT METHODOLOGY

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Continuous Assessment (40 marks) End Semester
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Examination
CA–1 CA–2 CA–3 CA–4 (60 marks)
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Written Test Written Test Quiz / Model Written

Mode (Unit – 1 & 2) (Unit – 3 & 4) MCQ Examination Examination
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Duration 2 hours 2 hours 1 hour 3 hours 3 hours

Exam Marks 60 60 40 100 100
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Converted to 20 20 10 10 60
Marks 40 60
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NOTE:
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CA–1 & CA–2 : Assessment test should be conducted. Best of one will be
considered for the internal assessment of 20 Marks.
CA–3 : Online quiz examination (MCQ) should be conducted covering the
complete syllabus. The marks should be converted to 10 marks for the internal
assessment
CA–4 : Model examination should be conducted as per the end semester question
pattern. The marks should be converted to 10 marks for the internal assessment.
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 Unit – I
ROLES AND RESPONSIBILITIES
OF MECHANICAL ENGINEER
1.1 INTRODUCTION TO MECHANICAL ENGINEERING
Engineering is the field that applies science and
mathematics to solve problems. Mechanical engineering is a
branch of engineering that involves design, analysis,
manufacturing and maintenance of mechanical systems. The
application base of mechanical engineering is extremely broad

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and diverse.

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Almost all inventions during the ancient period and a
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majority in the modern period are direct contributions of
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mechanical engineering. From small-scale machines to large-

scale structures, mechanical engineers are involved in almost
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every aspect of our daily lives.

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1.2 WHO IS A MECHANICAL ENGINEER?

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A mechanical engineer is a professional who transforms

an idea into a product or a mechanical system through research,
design, development, manufacturing, installation and
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maintenance of mechanical components and systems related

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with the product.

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1.3 JOB DESCRIPTION OF MECHANICAL ENGINEER

The job description of mechanical engineers varies
according to the sectors in which they work. It includes the
following:
1) Product design: Developing and modifying products to
satisfy functional and aesthetic criteria.
2) Analysis and testing: Analysis and testing to validate
product designs and ensure that they run effectively and
securely.
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1.1
 3) Material selection: Selection of materials for product
components based on durability and cost-effectiveness.
4) Prototyping: Development of prototypes, making
necessary adjustments and improvements.
5) Quality assurance: Ensuring products quality and safety
standards.
6) Research and development: Continuous innovation,
including research into new technologies and materials.

1.4 ROLES AND RESPONSIBILITIES

The common roles and responsibilities for mechanical

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engineers include:
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1) Designing and prototyping: Creating detailed plans and
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prototypes for new products or systems.

2) Analysis and testing: Conducting simulations and tests to
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ensure designs meet safety, quality, and performance

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standards.
3) Problem-solving: Diagnosing issues in existing
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machinery or systems and finding innovative solutions.

4) Collaboration: Working closely with various teams,
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including electrical and software engineers, to integrate

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mechanical systems.
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5) Production: Supervising the manufacturing of

mechanical components and machines.
6) Project management: Managing projects from concept to
completion, managing budgets and timelines.
7) Installation: Installing machines and mechanical parts at
the client location.
8) Maintenance and repairs: Keeping machinery and
systems in optimal working condition through regular
maintenance and repairs.
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1.2
 9) Research and development: Researching new
technologies and materials to improve mechanical
systems and products.

1.5 SCOPE AND OPPORTUNITIES FOR MECHANICAL

ENGINEER
Mechanical engineering is an ever-evolving field with new
technologies, concepts, and materials being developed daily.
Mechanical Engineering finds applications in all fields of
technology. Hence, mechanical engineers can get job in every
industry whether private or public sector.

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The scope and opportunities for mechanical engineer in
various sectors are explained below. A
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1) Manufacturing
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Manufacturing is the process of converting raw materials

into more valuable goods.
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Manufacturing engineering involves designing and

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developing manufacturing processes to improve

efficiency, productivity, and quality.
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The manufacturing industry plays a crucial role in the

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economic development of the country. Due to this, many

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employment opportunities were generated.

The top manufacturing industries in India are:
 Tata group of companies including Tata Motors, Tata
Steel, Tata Consultancy Services (TCS), Tata Power,
and Tata Chemicals.
 Reliance industries
 Mahindra group of companies
 Larsen & Toubro (L&T)
 Hindustan Unilever Limited (HUL)
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1.3
  Godrej group of companies
 Adani group of companies
 ITC Limited
 Nestle India, etc.
The various job titles of mechanical engineer in
manufacturing sector include:
 Production Engineer
 Quality Control Engineer
 Process Engineer
 Plant Manager

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 Maintenance Engineer
 Operations Manager, etc.
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2) Automobile
The automotive industry comprises a wide range of
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companies and organizations involved in the design,

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development, manufacturing, marketing, selling,

repairing, and modification of motor vehicles. It is one of
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the world's largest industries by revenue.

The top automobile industries in India are:
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 Maruti Suzuki India

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 Hyundai Motor India

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 Tata Motors
 Mahindra & Mahindra (M&M)
 Kia Motors
 Toyota Kirloskar India
 Honda Cars India
 Renault Motors
 Skoda Motors
 MG Motor India

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1.4
 The various job titles of mechanical engineer in
automobile sector include:
 Design Engineer
 Manufacturing Engineer
 Automotive Technician
 Quality Engineer
 Research and Development Engineer
 Production Engineer, etc.
3) Power generation
Power generation is important to fulfil the growing need
of the population. Power plants are industrial facilities that

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generate electricity from primary energy sources such as
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coal, natural gas, nuclear, solar, or wind energy.
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This field focuses on designing and developing renewable
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energy sources like wind turbines, solar panels, and

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hydroelectric power systems.

The major power generating industries in India are:
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 Power Grid Corporation of India Ltd.

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 NTPC (National Thermal Power Corporation)

 NHPC (National Hydroelectric Power Corporation)
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 Adani Power Limited

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 Tata Power Company Limited

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 JSW Energy Limited

The various job titles of mechanical engineer in power
generation sector include:
 Energy Engineer
 Thermal Engineer
 Renewable Energy Engineer
 Power Plant Engineer
 Operations Manager
 Research and Development Engineer, etc.
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1.5
4) Maintenance and Service
The main aim of maintenance is to maintain the
functionality of the equipment and to minimize its
breakdowns.
Maintenance engineers are responsible for maintaining
and repairing mechanical systems and equipment.
The various job titles of mechanical engineer in
maintenance and service sector include:
 Service Engineer
 Quality Engineer

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 Maintenance Engineer

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 Reliability Engineer G
 Maintenance Technician
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 Facility Maintenance Manager

 Operations Manager
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 Maintenance Supervisor
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 Property Manager, etc.

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5) Design
Industrial design is the professional practice of designing
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products, devices, objects, and services used by millions

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of people around the world every day.

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Design engineers work on creating and developing new

products and systems using computer-aided design (CAD)
software.
The major product design companies in India are:
 Brand Provoke
 Analogy Design
 Workshore
 Robosoft Technologies
 Criador Labs

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1.6
  Code Theorem
 Mouse & Cheese
 Teqzo Consulting
 Pixer, etc.
The various job titles of mechanical engineer in design
include:
 Design Engineer
 CAD Designer
 Drafting Technician
 Product Designer

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 Design Analyst
 Mechanical Designer
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 Project Engineer
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 3D Designer, etc.
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6) Quality control
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Quality control refers to the set of activities that are

designed to ensure that a product or service meets the
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specified quality standards. This is done through

inspections, testing, and reviews to identify and correct
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defects or problems in the product or service.

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Quality control is important for businesses because it helps

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to improve customer satisfaction, increase efficiency,

increase reputation, reduce costs, improve
competitiveness, and a variety of other benefits.
The various job titles of mechanical engineer in quality
control include:
 Quality Engineer
 Quality Supervisor
 Quality Analyst
 Quality Assurance Manager

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1.7
  Quality Inspector
 Test Engineer
 Quality Auditor
 Quality Coordinator
 Supplier Quality Engineer
 Quality Assurance Engineer
 Quality Control Engineer
 Quality Consultant

7) Materials management
Materials management is related to planning, purchasing,

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storing and providing the appropriate material of right
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quality, right quantity at right place in right time. It ensures
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smooth and unrestricted production, improves
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productivity, and reduces the cost.

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The various job titles of mechanical engineer in materials

management include:
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 Materials Manager
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 Supply Chain Manager

 Inventory Manager
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 Operations Manager
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 Purchasing Manager
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 Production Manager
 Logistics Manager
 Procurement Manager
 Warehouse Manager, etc.,
8) Logistics
Logistics is the process of planning and executing the
efficient transportation and storage of goods from the
point of origin to the point of consumption. The goal of
logistics is to meet customer requirements in a timely,
cost-effective manner.
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1.8
 The various job titles of mechanical engineer in logistics
include:
 Logistics Engineer
 Logistics Manager
 Logistics Analyst
 Inventory Control Manager
 Supply Chain Manager
 Procurement Manager
 Operations Manager
 Transportation Manager

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 Facilities Manager
 Service Manager
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REVIEW QUESTIONS
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1) Who is a mechanical engineer?

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2) Describe the job of a mechanical engineer.

3) What are the roles and responsibilities of a mechanical engineer?
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4) List out the various job titles of a mechanical engineer.

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5) List out the various sectors providing job opportunities for

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mechanical engineer.
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6) Explain the scope and opportunities for mechanical engineer

in the following sectors : (a) Manufacturing (b) Logistics
7) What are the scope and opportunities for mechanical engineer
in the field of Automobile and Materials management.
8) Describe the scope and opportunities for mechanical engineer
in the following : (i) Power Generation (ii) Quality Control
9) Write short notes on the scope and opportunities for mechanical
engineer in (a) Design (b) Maintenance and Service

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1.9
 Unit – II
Chapter 2.1. ENGINEERING MATERIALS
2.1.1 IMPORTANCE OF MATERIALS
A vast range of materials are available today for the choice
of engineer. The best material is one which serves the required
objective at the minimum cost. The following are the importance
of materials :
Materials are the building blocks of modern society.
Use of materials is an essential requirement for the

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development of engineering and technology.

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Materials are the main component of all products,
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structures, and machines.
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They provide the basis for manufacturing, fabrication,

operations, constructions, etc.
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2.1.2 TYPES OF MATERIALS

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The types of materials are:

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1) Metals 2) Ceramics 3) Polymers

4) Composites 5) Semi-conductors
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1) Metals
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All metals are classified as follows :

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Ferrous metals: These are metals which contain iron. All

ferrous metals are magnetic and give little resistance to
corrosion.
Example: Cast iron, wrought iron, mild steel, stainless
steel, high speed steel (HSS), etc.
Non-ferrous metals: These are metals which do not
contain any iron. They are not magnetic and are usually
more resistant to corrosion than ferrous metals.
Example: Aluminium, copper, lead, zinc, tin, etc.

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2.1
 Alloys: An alloy is a type material in which one or more
alloying elements have been added to give it special
properties.
Example: Brass, bronze, nichrome, solder, duralumin,
German silver, gun metal, bell metal, etc.
Uses and applications of metals
Automotive parts, industrial machinery, machine tools,
kitchen wares, steel structures, forgings, castings, surgical and
dental instruments, food processing machinery, etc.
2) Ceramics

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Ceramics are solid compounds consisting of metallic or
non-metallic elements. They are mainly oxides, nitrides, and
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carbides. Ceramics have excellent corrosion and wear
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resistance, high brittleness, high melting temperature, high
PA

stiffness, and low electrical and thermal conductivity.

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Example: Glasses, cements, clay products, refractories,

and abrasives.
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Uses and applications: Tiles, bricks, terracotta, pottery,

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drain pipes, covers for electrical cables, optical

instruments, spark plugs, fiber optics, artificial joints,
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space shuttle tiles, cooktops, race car brakes, etc.

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3) Polymers
Polymers are large molecules made up of repeating small
simple chemical units. Polymers are classified as thermoplastic
polymers, thermosetting polymers, and elastomers.
Example: Plastics, rubbers, fibers, adhesives, and
coatings.
Uses and applications: Packaging, stationeries, plastic
products, aircraft, construction, rope, toys, plumbing pipes,
electrical switches, kitchen products, insulators, computer
discs, paints, etc.
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2.2
4) Composites
A composite is a material in which one or more mutually
insoluble materials are mixed or bonded together. They are
classified as particulate composites, fibrous composites, and
laminated composites.
Example: Plywood, Carbon fiber-reinforced polymers
(CFRP), Glass fiber-reinforced polymers (GFRP), Metal
matrix composites (MMC), Ceramic matrix composites
(CMC), etc.
Uses and applications: Aerospace, architecture,

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construction, automotive, marine, military, pipings,
storage tanks, sports, transportation, etc.
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5) Semi-conductors
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Semiconductors have electrical properties intermediate

between those of conductors and insulators. They are widely
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used in electronics and computer industry.

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Example: Silicon, Germanium, Selenium, Gallium, etc.

Uses and applications: Mobile phones, laptops, games
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consoles, microwaves, refrigerators, digital watches, GPS

systems, fitness trackers, televisions, lighting, LED
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displays, Solar cells, trains, ATMs, etc.

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2.1.3 MECHANICAL PROPERTIES OF MATERIALS

1) Elasticity
The property of material by which a body regains its
original shape and size after deformation when applied
forces are removed is known as elasticity.
The elasticity property is desirable in materials used for
manufacturing of tools and machine elements.
Example: Steel and rubber are some materials having
good elasticity.

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2.3
2) Plasticity
Plasticity is the property of a material by which a body
retains the deformation due to applied load without
rupture, even after the removal of applied load.
Plasticity plays an important role in manufacturing
processes like forming, forging, swaging, coining,
extrusion, etc.
Example: Clay and lead are some materials having good
plasticity.

3) Ductility

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Ductility is the property of a material by which the material
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can be drawn out or elongated into thin wires without
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rupture by applying a tensile force.
PA

This property is very important in manufacturing

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processes like rolling, wire drawing, etc.

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Example: Mild steel, copper, aluminium, zinc, gold and

platinum are some materials having high ductility.
PA

4) Malleability
Malleability is the property of a material by which the
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material can be flattened into thin sheets without cracking

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by hot or cold working processes.

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This property is very important in manufacturing

processes like forging, hot rolling, drop forging, wire
drawing, etc.
Example: Mild steel, wrought iron, copper and aluminium
are some materials having high malleability.

5) Machinability
Machinability is the property of a material by which the
material can be easily machined by cutting tools in various
machining operations.
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2.4
 The machinability of different materials can be compared
with the help of machinability index.
Example: Grey cast iron has excellent machinability.

6) Castability
Castability is the property of a material by which the
material can be easily cast into different size and shapes.
Castability of a material can be decided by considering
the solidification rate, shrinkage during cooling, gas
porosity and hot strength.
Example: Grey cast iron has good castability.

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7) Weldability A
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Weldability is the property of a material by which the
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material can be welded into a specific and suitable

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designed structure and to perform satisfactorily in the

desired objective.
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Example: Steel, aluminium, copper and brass have good

PA

weldability.

8) Strength
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Strength is a property of a material by which the material

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can withstand or resist the action of external force or load

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without breaking or yielding.

This property plays an important role in the designing of
various structures and machine elements.
Example: Tungsten, steel, titanium and chromium have
more strength.

9) Stiffness or rigidity
Stiffness is the property of a material to resist elastic
deformation or deflection due to the applied load. It is also
known as rigidity.
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2.5
 This property is very important in the design of beams,
shafts and springs.
Example: Steel, aluminium and brass are the some
materials having high stiffness.

10) Toughness
Toughness is the property of a material to resist the
fracture by absorbing energy due to heavy shock loads or
blow, without rupture.
This property is desirable in structural members and
machine elements which are subjected to absorb shock

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and vibrations.
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Example: Cast iron, mild steel and brass are some
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materials having high toughness.
PA

11) Brittleness
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Brittleness is the property of a material by which the material

TH

will fail or fracture all of sudden without any significant

deformation. This property is opposite to ductility.
PA

This property is desirable in machine parts which may be

subjected to sudden compressive loads.
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Example: Cast iron, concrete, glass and stone are some

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material having high brittleness.

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12) Hardness
Hardness is the ability of a material to resist surface
penetration, abrasion and scratching.
It is an important property involved in the design of
machine members such as gears, cams, chain sprockets,
etc. which are under constant rubbing action.
Example: Hard steel, cast iron, glass and diamond are the
some materials having good hardness.

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2.6
13) Wear resistance
Wear resistance is the property of a material to resist wear.
Wear resistance can be increased by increasing the
hardness of the working surface by case hardening
process.
Example: Steel, aluminum, stainless steel, and titanium
are some materials having high wear resistance.

14) Fatigue
Fatigue of a material may be described as the failure of the
material when subjected to a number of cyclically

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changing loads in which the maximum stress developed in

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each cycle is well within the elastic range.
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This property is important in machine elements such as
PA

motor shafts, bolts, springs, gear teeth, valves and turbine

blades.
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Example: Load on piston and connecting rod of a double

TH

acting engine are some components subjected to fatigue.

PA

15) Fatigue strength

The stress at which a material fails by fatigue is known as
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fatigue strength. Fatigue strength decreases when

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temperature increases.
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It is mainly affected by the type of loading and working

nature of the material.

16) Endurance limit or fatigue limit

Endurance limit or fatigue limit is a maximum stress below
which a load may be repeatedly applied at infinite number
of times without causing failure of material by fatigue.
This limiting stress is most important while designing
machine elements which are subjected to repeated or
cyclic loading.

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2.7
17) Creep
Creep is the property of a material by which the material
is deformed slowly and progressively under a constant
load over a long period.
Example: Creep is considered important in I.C engine
components, components of gas turbines, steam turbines
and boilers working at high temperature, components of
rockets, missiles, etc.

2.1.4 THERMAL PROPERTIES OF MATERIALS

1) Specific heat capacity

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It is defined as the quantity of heat required to raise or

A
lower the temperature of the unit mass of the material through
G
one degree. Materials with high specific heat capacity require
PA

more energy to raise their temperature.

IP

2) Thermal conductivity
It is defined as the amount of heat conducted in a unit time
TH

through a unit area normal to the direction of heat flow.

Materials with high thermal conductivity can transfer heat
PA

quickly. The thermal conductivity of pure metals increases as

temperature is lowered.
L
A

3) Thermal expansion
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Thermal expansion is the tendency of a material to expand

or contract in response to changes in temperature. The increase
in length per unit length per degree rise in temperature is called
coefficient of linear expansion. Materials with high thermal
expansion coefficients expand more when heated.
4) Melting and boiling point
The melting point is the temperature at which a solid
material melts and becomes a liquid.
The boiling point is the temperature at which a liquid
material boils and becomes a gas.
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2.8
5) Thermal shock
Thermal shock is the effect of a sudden change of
temperature on a material. Thermal shock resistance can be defined
as the ability of material to withstand thermal stresses due to sudden
changes in the temperature at the surface of a solid body.

2.1.5 ELECTRICAL PROPERTIES OF MATERIALS

1) Capacitance: Capacitance is the capability of a material to
store electric charge. The capacitance between two
conductors is a function of the geometry only.
2) Electrical conductivity: This is the ability of a material to

M
conduct electrical current. Metals like copper and gold have
high conductivity.
A
G
3) Electrical resistivity: The opposite of conductivity is
PA

resistance. It is defined as ability of the material to resist the

flow of electrical current. Materials with high resistance are
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used as insulators. Example : Glass, plastic and silicone.

TH

4) Dielectric strength: It is the maximum electric field that the

PA

material can withstand under ideal conditions without

undergoing electrical breakdown.
2.1.6 MAGNETIC PROPERTIES
L
A

1) Magnetic field: The magnetic field is an imaginary line of

K

force around a magnet which enables other ferromagnetic

materials to get repelled or attracted towards it.
2) Magnetic intensity: The external magnetic field that is only
produced by electric current flowing in a material is known
as magnetic intensity or magnetic field strength.
3) Magnetic flux density: The density of magnetic field lines
that pass through the material per square meter is known as
magnetic flux density.

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2.9
 4) Retentivity: It is the ability of a material to retain
magnetization.
5) Coercivity: It is the ability of a material to withstand the
external magnetic field without being demagnetized.
6) Magnetic susceptibility: It is the measure of the
magnetisation of a material in response to the applied
magnetic field.
7) Magnetic permeability: It is the measure of the resistance
of a material against the formation of a magnetic field.

2.1.7 CHEMICAL PROPERTIES

M
A
1) Reactivity: The tendency of material to combine chemically
G
with other materials is known as reactivity.
PA

2) Flammability: The tendency of matter to burn is known to

as flammability.
IP

3) Toxicity: Toxicity refers to the extent to which a chemical

TH

element or a combination of chemicals may harm an

organism.
PA

4) Acidity or Alkalinity: Acidity of Alkalinity of material

indicates that how they react with other materials. It is
L

decided by the pH value of the material. pH value of 7 is

A

considered to be neutral. The materials with pH value below

K

7 are called Acetic and materials with pH value above 7 are

called alkane.
5) Corrosion resistance: It is the ability of a material to resist
the oxidation in atmospheric condition.

,
2.10
 Unit – II
Chapter 2.2. METAL FORMING
2.2.1 METAL FORMING – DEFINITION
Metal forming can be defined as a process in which the desired
size and shape are obtained through the deformation of metals
plastically under the action of externally applied forces. Metal
forming is highly economical because there is no metal wastage.

2.2.2 TYPES OF METAL FORMING

Metal forming processes are classified in to the following

M
two types:
a) Hot working b) Cold working
A
G
a) Hot working
PA

Hot working is the process of heating the metal above its

IP

recrystallization temperature to undergo plastic deformation and

to get the required shape.
TH

During heating, a change in grain structure of metal occurs

PA

to form new grains at particular temperature. This temperature is

called recrystallization temperature. Generally, the recrystallization
temperature of metal will be about 30 to 40% of it melting point.
L
A

Examples of hot working operations :

K

1) Rolling 2) Forging 3) Swaging

4) Extrusion 5) Drawing 6) Hot spinning
Advantages of hot working
1) The toughness and ductility of metal can be improved.
2) The hardness due to the plastic deformation can be removed.
3) No internal stresses are produced in the metal.
4) Less amount of force is sufficient to deform the metal.
5) Defects like cracks, blow holes, porosity will not occur in
the metal.

,
2.11
 6) As the grain structure of metal is refined, the strength can
be increased.
7) It is a quick and economical process.
8) All methods can be formed to required shape by this method.
Limitations of hot working
1) Poor surface finish due to oxidation or scale formation .
2) De-carburization takes place on the metal surface.
3) Less dimensional accuracy
4) High tooling cost
5) Handling of hot worked parts is difficult

M
b) Cold working
A
G
Cold working of a metal is carried out below its
PA

recrystallisation temperature. Cold working involves plastic

deformation of a metal, which results in strain hardening.
IP

Examples of cold working operations

TH

1) Cold rolling 2) Extrusion 3) Wire drawing

PA

4) Forging 5) Shearing 6) Bending

7) Pressing 8) Squeezing 9) Embossing
10) Coining 11) Cold spinning 12) Shot peening
L
A

Advantages of cold working

K

1) Mechanical properties are improved

2) Smooth surface finish can be easily produced.
3) Better dimensional accuracy is achieved.
4) Strength and hardness of the metal are increased
5) No formation of oxide
6) There is no possibility of decarburization of the surface
7) It is easier to handle cold parts.

,
2.12
Limitations of cold working
1) The ductility of metal is decreased
2) The grain structure is distorted.
3) Residual stresses are set up in the metal.
4) Strain hardening occurs.
5) Metal surfaces must be clean and scale free before cold
working.
6) Greater force is required
7) Only small sized components can be produced.
Comparison of hot working and cold working

M
Hot working Cold working
1) It is carried out above the A
It is carried out below the
G
recrystallisation recrystallisation temperature.
PA

temperature and below the

melting point.
IP

2) No internal stresses are Internal or residual stresses

TH

developed. are developed.

3) The grain structure is The grain structure is
PA

refined. distorted.
4) Close tolerance cannot be Better tolerance can be
L

maintained. maintained.
A

5) Poor surface finish is Better surface finish is

K

obtained. obtained.
6) Less work hardening High work hardening occurs.
occurs.
7) Lesser force is required. Greater force is required.
8) Components of any size can Only small size components
be produced. can be produced.
9) Higher tooling cost. Lesser tooling cost.
10) Handling of parts is Handling of parts is easy.
difficult.

,
2.13
2.2.3 DROP HAMMER

Ram

Upper die
Metal

Lower die

Anvil

M
A
G Base
PA

Fig.2.1 Drop hammer

IP

Drop hammers are used in drop forging operations. Drop

TH

hammers like gravity hammer, power drop hammer and air lift
hammer can be used. Drop forging is the process of making the
PA

heated metal into required shape by placing it between two

closed dies and pressing with the help of drop hammer.
L

The lower die is fitted on the anvil and the upper die is
A

fitted with the ram. The heated metal is placed over the lower
K

die. When the ram falls down, the heated metal fills the die
cavities due to the impact force of the upper die. Thus the
required shape is obtained.
Components with simple shapes are forged in single
operation. Components with complicated shapes are forged in
several steps. Roughing die, semi finishing die and finishing die
are used for such operations.
Application
Crank, crank shaft, connecting rod, levers, camshaft, etc.
can be produced by drop forging using drop hammers.
,
2.14
Advantages
1) It is suitable for mass production.
2) The strength of the component is high.
3) Less material wastage.
Disadvantages
1) Large anvil and strong foundation are needed.
2) More noise and vibration.
3) The die may wear our quickly.

2.2.4 ROLLING
Original grains Refined grains

M
A
G
PA

Elongated grains
IP

Rotating roll
Fig.2.2 Hot rolling
TH

Rolling is a process of forming metal to the required shape

PA

by passing it between rotating rolls. When the metal to be rolled

is heated above its recrystallization temperature, it is called hot
rolling. The periphery of the roll is made to the required shape.
L
A

When the metal passes between the rolls, plastic

K

deformation of metal occurs due to the high compressive stress.

The metal grains elongate in the direction of rolling. So the cross
section of metal is reduced and the length is increased. Hot
rolling is done by using two or three sets of roll mills. Rolling is
done progressively until the required shape is obtained.
The casting got from foundry shop is called ingot. First the
heated ingots are rolled to obtain semi-finished shapes like bloom,
billet and slab. I-section, T-section, channels and angles are
formed by hot rolling the blooms. Rounds, squares and wires are
obtained from billet. Plates and sheets are obtained from slab.
,
2.15
Applications
Rolling is used to produce components having constant
cross-section throughout its length. This includes sheets, plates,
rounds, squares, wires, hexagonal bars, I-sections, T-sections,
channels, angles and many other shapes.

2.2.5 ROLL FORGING

Upper roll

Work piece
Groove

M
A
G
PA

Product
Lower roll
IP

Fig.2.3 Roll forging

TH

In plain rolling, components with uniform cross section

PA

are produced. Roll forging is a process of producing components

with varying cross sections by pressing the heated work piece
between two rotating rolls.
L
A

The periphery of the rolls used in this method will not be

K

round. According to the required shape of the component, the

rolls have grooves of different radii. When the heated work piece
passes between the rolls, it gets the shape of the grooves in the
roll. Thus the varying cross section is obtained in the component.
In this process, the cross section or work piece is decreased and
the length is increased.
Applications
Automobile axles, levers, leaf springs, tapered tube are
produced by roll forging.

,
2.16
2.2.6 EXTRUSION
Extrusion is a simple compressive metal forming process.
The extrusion setup consists of a cylinder container. A die plate
with the necessary opening is fixed on one end of the container.
A plunger or ram is fitted on the another end.

Die

Ram

Extruded
product
Cylinder Metal billet

M
(a)
(a)Direct
Directextrusion
extrusion
A
G
Metal billet Die Ram
PA

Ram direction
IP
TH

Extrusion
direction
PA

Cylinder Extruded product

(b)
(b)Indirect extrusion
L

Indirect extrusion
A
K

Metal billet Die

Cylinder Extruded
product

Mandrel
Ram
(c) Tube extrusion
Fig.2.4 Types of extrusion

,
2.17
Working
The heated metal billet is placed inside the container. A
compressive force is applied to the billet through the ram. The
force is applied either hydraulically or mechanically. Now the
ram pushes the billet towards die. Due to the high compressive
force, the heated metal flows through the die opening and
converted into desired shape.
Hot extrusion process is classified as follows :
(a) Direct or forward hot extrusion: In this type, metal is
forced to flow in the direction of ram movement. This
process requires higher force due to higher friction

M
between billet and container.

A
(b)Indirect or backward hot extrusion: In this type, metal is
G
forced to flow in the opposite direction of ram movement.
PA

The metal billet remains stationary. The die fitted with the
hollow ram moves into the billet. This process requires
IP

less force due to low friction between billet and container.

TH

(c) Tube extrusion: This process is similar to direct extrusion.

PA

An additional mandrel is used to restrict flow of metal for

production of seamless tubes.
L
A

Applications
K

The hot extrusion process is widely used to manufacture

products from aluminium, copper and their alloys. This includes
rods, bars, wires, tubes, structural shapes, aircraft parts, etc.

2.2.7 MECHANICAL PRESS

Press is a machine used for pressing or cutting the metal
to get required shape by applying mechanical force or pressure.
It is used for producing finished products from sheet metal at
fast rate. So it is suitable for mass production. The important
parts of mechanical press are explained below.

,
2.18
 Crank Fly wheel

Connecting rod

Ram

M
Die
Punch

A
G
PA

Fig.2.5 Mechanical press

IP

1) Base : It supports the press. Bed and frame are fitted over the base.
TH

2) Frame : It houses the driving mechanism. The ram slides

over the guide ways provided in the frame.
PA

3) Bolster plate : It is a heavy plate fitted over the bed. Die

assembly is fitted on the bolster plate.
L

4) Driving mechanism : Crank and connecting rod drive is

A

generally used in mechanical press. Ram is connected to the

K

crank through connecting rod. When crank shaft rotates, ram

slides up and down.
5) Fly wheel : It is a large wheel fitted at the end of driving
shaft. It stores the energy during idle stroke and gives the
energy to deform the work piece during working stroke.
6) Punch : Punch is fitted in the punch holder. The punch
holder is fitted at the bottom of ram. The punch moves up
and down along with the ram.
7) Die : Die is fitted in the stationary die holder on the bolster plate.

,
2.19
Working principle
Suitable punch and die are fitted in the press. Work piece
is held between the punch and die. Crank shaft is rotated by a
motor. Crank and connecting rod drive converts the rotary
motion into reciprocating motion. So the ram moves up and
down. When the ram moves down, it presses the work piece and
required operation is performed. Different die and punch set are
used in the press for various operations.

Applications
Mechanical presses are widely used in sheet metal
operations such as pressing, bending, curling, piercing, deep

M
drawing, straightening, trimming, assembling of various steel
components, etc. A
G
PA

2.2.8 WIRE DRAWING

IP

Wire drawing is a metal forming process used to reduce the

cross-section of a wire by pulling it through a single die or series of
TH

dies. The drawing die is usually made of carbide or diamond.

PA

Casing
L
A
K

Hot rolled rod

Direction
of feed

Die

Fig.2.6 Wire drawing

,
2.20
 Before the wire is drawn, it must be cleaned to remove dirt
or impurities. It is normally done by acid pickling. Lubricant is
applied to reduce friction during the drawing process. The end of
the wire is made pointed so that it can be easily inserted into the
die. This is done using a wire pointing machine or by hammering.

The wire is fed through the first die and pulled by a

powerful motor. As the wire is drawn through the die, its diameter
is reduced and length increases. This process is repeated through
a series of dies until the required diameter is achieved.

The wire should be annealed to relieve the stresses and

M
strain caused by the drawing process. Annealing involves
A
heating the wire to specified temperature and then cooling it
G
slowly at room temperature. Annealing makes the wire more
PA

ductile for further drawing or fabrication process.

IP

Applications
TH

Wire drawing is used to produce electrical wires, cables,

tension-loaded structural components, springs, paper clips,
PA

spokes for wheels, jewellery, stringed musical instruments, etc.

L
A
K

,
2.21
 Unit – II
Chapter 2.3. METAL JOINING
2.3.1 METAL JOINING PROCESS
Metal joining is one of the manufacturing processes by
which two or more metal parts are assembled together to obtain a
single unit. Joining processes can be broadly classified into the
following two groups :
a) Temporary joining processes : These processes allow
easy dismantling of joined components without rupturing
them. It enables assembly and disassembly of joined

M
components as and when required without harming them.
A
Example: Fasteners (bolts and nuts), press fits,
G
mechanical joints, etc.
PA

b) Permanent joining processes : These processes do not

IP

allow disassembly of joined components without

TH

rupturing them.
Example: Welding, brazing, soldering riveting, etc.
PA

2.3.2 DIFFERENCE BETWEEN TEMPORARY AND

PERMANENT JOINING
L
A

Temporary Joining Permanent Joining

K

1) A temporary joint can be A permanent joint cannot be

dismantled without breaking dismantled without breaking
the assembled parts. parts.
2) It is suitable where frequent It is suitable where joint is to
assembly and disassembly be fixed for longer period.
are required.
3) Strength of joint is low. Strength of joint is high.
4) Temporary joints are not Permanent joints are leak-
leak-proof. proof.
5) Cost for inspection of parts Cost for inspection of parts is
is low. high.

,
2.22
 Temporary Joining Permanent Joining
6) Repair and maintenance of Repair and maintenance of
parts is easy. parts is difficult.
7) Example: Bolting, press fit, Example:Welding, soldering,
mechanical joints, etc. brazing, riveting, etc.
2.3.3 TYPES OF TEMPORARY JOINTS
The major types of temporary joints are explained below :
1) Bolted joints
A bolted joint consists of a long bolt with external threads
and a bolt with mating internal threads. The bolt is inserted
into the holes drilled in the parts to be joined. A nut is

M
screwed and secured on the threads at the end of the bolt.
A
The bolted joints can bear tensile, shear and bending forces.
G
Applications: Construction, assembly, fabrication,
PA

machine design, pipe flanges, automotive engines, etc.

IP

2) Press fit joint

TH

Press fit joint is achieved by inserting a shaft tightly into a

slightly smaller hole in another part. The parts are held
PA

together by constant stress and friction. The parts may be

joined using a tap from a hammer or forced together using
a hydraulic press.
L
A

Applications: Bearing-shaft assembly, automobile,

K

plumbing, electronics, robotics, etc.

3) Mechanical joints
A mechanical joint is a section of a machine which is used
to connect one or more mechanical parts to another. Most
mechanical joints are designed to allow relative movement
of the parts in one degree of freedom. Pin joint, ball joint,
knuckle joint, cotter joint, universal joint are some of the
examples of mechanical joints.
Applications: Assembly, machine design, automotive
engines, robotics, etc.
,
2.23
2.3.4 TYPES OF PERMANENT JOINTS
The major types of permanent joint are explained below :
1) Welding
Welding is the process of joining similar or different metal
by heating. Welding can be done with or without the application of
pressure. During welding, the edges of metal pieces are either
melted or brought to plastic stage. Welding gives a permanent joint.
Types of welding
The two types of welding processes are :
(a) Plastic welding or pressure welding: In this type of

M
welding, the metal pieces are heated to plastic stage and

A
joined by applying sufficient pressure.
G
Example: Electric resistance welding such as spot
PA

welding, butt welding, seam welding, projection

welding, etc.,
IP

(b) Fusion welding or non- pressure welding: In this type

TH

of welding, the metal pieces are melted and joined with

PA

the help of filler material without applying pressure.

Example : Gas welding, electric arc welding such as
L

carbon arc welding, metal arc welding, Metal Inert Gas

A

(MIG) welding, Tungsten Inert Gas (TIG) welding,

K

submerged arc welding, electro slag welding, etc.

Applications of welding
Fabrication of automobile bodies, air craft, machine
frames, boilers, ship building, railway wagons, etc.

2) Soldering
Soldering is the process of joining two similar or
dissimilar metals by using a low melting alloy called solder.
Solder is an alloy of tin and lead. It melts at low temperature
(150°C to 350°C). The edges are not melted in this method.

,
2.24
Applications
Connections in wireless set, T.V. sets, etc.
Wiring joints in electrical connections, battery and other
terminals.
Radiator brass tubes for motor car.
Copper tubing carrying liquid fuel, gas or air used in
engines.
Drain water pipes.

3) Brazing

M
Brazing is the process of joining two similar or dissimilar
metals by using a high melting alloy called spelter. Spelter is a
A
mixture of copper and zinc alloy. The melting temperature of
G
spelter (600°C) is lower than the melting temperature of work
PA

piece. The edges of work pieces are not melted in this method.
IP

Applications
TH

Radiator works, joining pipes with drums and tanks,

joining carbide tips on tool shank, etc.
PA

4) Riveting
L

Riveting is a method of joining two or more components

A

together using rivets. Rivets are cylindrical metal fasteners with

K

a head on one end and a tail on the other. They are inserted
through holes in the components to be joined and then deformed
to create a permanent joint. The riveting may be done by using
hammer or riveting machine. The two types of riveted joints are
lap joint and butt joint.

Applications
Structural works, ship building, bridges, roof trusses,
tanks, boiler shells, etc.

,
2.25
 REVIEW QUESTIONS

ENGINEERING MATERIALS
1) List out the importance of materials.
2) Explain the various types of materials. Give examples and
applications.
3) List out the various mechanical properties.
4) Explain the following mechanical properties :
(a) Elasticity (b) Ductility (c) Machinability (d) Machinability
5) Write short notes on the following :

M
(a) Plasticity (b) Malleability (c) Castability (d) Strength
6) Explain the following : A
G
(a) Stiffness (b) Brittleness (c) Wear resistance (d) Fatigue
PA

strength
IP

7) Briefly explain the following properties :

(a) Toughness (b) Hardness (c) Fatigue (d) Creep
TH

8) Explain the various thermal properties of materials.

PA

9) Write short notes on various electrical properties of materials.

10) List and explain the various magnetic properties.
L

11) Briefly explain the important chemical properties of materials.

A
K

METAL FORMING
12) Explain hot working and cold working. Give examples.
13) List out the advantages and limitations of hot working.
14) State the advantages and limitations of cold working.
15) Compare hot working and cold working.
16) Explain the working of drop hammer with neat sketch.
17) Explain: (a) Rolling (b) Roll forging
18) Explain extrusion process with neat sketches.

,
2.26
19) Explain the construction and working of mechanical press
with a sketch.
20) With a neat sketch, explain wire drawing operation.

METAL JOINING
21) Write the differences between temporary and permanent
joining.
22) Explain various temporary joints.
23) Write short notes on welding.
24) Explain: (a) Soldering (b) Brazing (c) Riveting

M
A
G
PA
IP
TH
PA
L
A
K

,
2.27
 Unit – III
FUNDAMENTALS OF MACHINE TOOLS
3.1 INTRODUCTION TO MACHINE TOOLS
A machine tool is a power-driven machine used for
removing material by machining operations. Machining is the
process of removal of material from the workpiece to obtain a
finished product of the desired size, shape and surface quality.
The common machine tools include:
1) Lathes 2) Planers

M
3) Shapers 4) Slotters
5) Milling machines A
6) Drilling machines
G
PA

7) Boring machines 8) Grinding machines

9)Broaching machines
IP

3.2 LATHE
TH

Lathe machine is one of the oldest machine tool. It was

very important to the industrial revolution. All the machine tools
PA

available nowadays are developed on the basis of lathe. Hence it

is called as mother of machine tools.
L
A

Principle of lathe
K

Lathe is used for removing metal from cylindrical work

piece to get required shape and size. The work piece is held in
the lathe and rotated about its axis. The single point cutting tool
is moved parallel to the axis of work piece to produce cylindrical
surface.

3.2.1 Description of lathe

A lathe has the following principal parts.
1) Bed 2) Head stock 3) Carriage 4) Tail stock

,
3.1
1) Bed
The lathe bed is made strongly with cast iron. It withstands
the cutting force and vibrations. The head stock is mounted on
the left, the tail stock at the right and the carriage in the middle
of bed. The carriage and tail stock move over the flat or ‘V’
shaped guide ways on the bed.
Tool post
Head stock Cross slide Compound slide
Tail stock
Saddle

M
Apron

A
G
PA

Lathe bed
IP

Feed rod
Carriage
TH

Lead screw
PA

Fig.3.1 Lathe
2) Head stock
L

The head stock with a hollow spindle is mounted on the bed.

A

Chuck or face plate can be fitted in the threaded spindle nose.

K

Driving and speed changing mechanisms are provided in the head

stock. The two types of head stock are back geared head stock and
all geared head stock.

3) Carriage
Carriage moves on the guide ways of lathe bed parallel to
the spindle axis. The carriage is used for giving various
movements to the tool. It can be moved by hand or by power.
Saddle, cross slide, compound rest, tool post and apron are
mounted on the carriage.

,
3.2
 Saddle: It is a ‘H’ shaped casting. Saddle slides over the
guide ways of bed.
Cross slide: It is mounted over the saddle. It moves
perpendicular to the lathe axis. The cross slide can be
moved by hand or by power.
Compound rest or compound slide: It is fitted on the cross
slide. Compound rest has a swivel base graduated with
degrees. The swivel base can be tilted to any required
angle. Compound rest is used during taper turning. Hand
feed only can be given.
Tool post: Tool post is fitted in the T-slots provided on the

M
compound rest. The tool is clamped in the tool post. The four
A
types of tool posts are : (i) Single screw tool post (ii) Open
G
side tool post (iii) Four bolt tool post (iv) Four way tool post
PA

Apron: Apron is fitted with the saddle and hangs in front

IP

of the carriage. The carriage movement is controlled by

the gears, levers and clutches provided in the apron. The
TH

carriage can be moved parallel to lathe axis by hand wheel.

Thread cutting operation can be performed by engaging
PA

the half nut lever in the apron with the lead screw.
L

4) Tail stock
A

The tail stock is mounted at the right side of the lathe bed.
K

It can be moved over the guide ways on the bed and positioned at
any required place. The barrel in the tail stock has a hollow
spindle. The spindle can be moved axially by rotating the hand
wheel connected with a screw. The tail stock can be moved
crosswise by loosening the set over screw.
Functions of lathe
The main function of lathe machine is to remove excess
material in the form of chips by rotating the work piece against
a stationary cutting tool. The material removal from the
workpiece is done by the following lathe operations.
,
3.3
 1) Straight turning 2) Step turning 3) Facing
4) Chamfering 5) Grooving 6) Parting off
7) Knurling 8) Drilling 9) Reaming
10) Boring 11) Taper turning 12) Thread cutting

3.3 DRILLING MACHINE

Drilling is the process of producing circular holes in a
work piece. The machine used for this operation is called drilling
machine and the tool is called drill or drill bit.
Principle of drilling
The workpiece is held securely in place on the drill table

M
using vises and clamps. The hole is produced by giving axial
A
movement to the rotating drill against the work piece.
G
PA

3.3.1 TYPES OF DRILLING MACHINES

1) Portable drilling machine
IP

2) Bench type - sensitive drilling machine

TH

3) Floor type - upright drilling machine

4) Radial drilling machine
PA

(i) Plain type (ii) Semi universal type (iii) Universal type
5) Gang drilling machine
6) Multi spindle drilling machine
L
A

7) Deep hole drilling machine

K

(i) Vertical type (ii) Horizontal type

3.3.2 UPRIGHT DRILLING MACHINE

Description
It is a heavy duty drilling machine mounted on the floor.
It can be used for drilling holes up to 25mm diameter. The
important parts are explained below.
1) Base: The base is mounted on the floor. It supports other
parts of the drilling machine. The top surface of the base
is machined accurately. T-slots are provided for holding
large work pieces.
,
3.4
 2) Column: It is mounted vertically on the base. It is also
called as upright. It supports the table, spindle head and
driving mechanism. It is designed so as to withstand heavy
cutting forces.
3) Table: The rectangular or circular table is fitted to the
column. T-slots are provided on the table to hold work
pieces. The table can be moved up and down along the
column. It can be rotated about its own axis. It can also be
adjusted radially towards or away from the column.
4) Spindle head: At the top of the column, a motor is fitted on
one side. The spindle head is fitted on the other side. The

M
motor drives the spindle through V-belt and step cone pulley.
A
The lower end of the spindle has Morse taper to hold the drill
G
bit or drill chuck.
PA
IP

Main drive
TH

Feed handle
Motor
PA

Sensitive
feed handle
L
A

Vetical column
K

Spindle
Table locking
handle

Table

Base

Fig.3.2 Upright drilling machine

,
3.5
Principle of operation of drilling machine
The spindle head has a hollow cylindrical shaped part
called quil. The quil has a rack cut on its outer surface. The quil
can be moved up and down by engaging pinion with the rack.
The revolving spindle is held inside the quil with bearing
supports. So the quil can be moved up and down while the
spindle rotates.

The spindle has a long key way at its upper end. A bevel
gear connected with the spindle can slide on these guide ways.
This arrangement allows the bevel gear to transmit the drive to
the spindle, while the spindle moves up and down.

M
A
The lower end of the spindle has a hole with Morse taper
G
to hold the drill bit or sleeve. The taper shank fits in to the taper
PA

hole to get positive drive. The work piece is fitted on the table
by using suitable work holding device. The drilling is performed
IP

on the work piece by feeding the spindle manually or automatic.

TH

3.4 MILLING MACHINE

PA

Milling is the process of removing metal from the work

piece by using a multi point cutter. The machine used for this
process is known as milling machine.
L
A

Principle of milling
K

When the work piece is fed against the cutter, the metal is
removed in the form of chips. As multi point cutter is used, metal
is removed quickly. The milling processes are classified in to
two types.
Up milling or conventional milling: Metal is removed
when the cutter teeth move upwards. The cutter rotates
opposite to the direction of feed of work piece.
Down milling or climb milling: Metal is removed when
the cutter teeth move downwards. The cutter rotates in the
same direction as the feed of work piece.
,
3.6
3.4.1 HORIZONTAL MILLING MACHINE
Over arm

Yoke
Cutter
Arbor

Spindle
nose
Collars in arbor
Handle for table feed Guide ways
Saddle

Column

M
A
Knee G
Handle for knee
PA
IP

Base
TH

Fig.3.3 Horizontal milling machine

Description
PA

The spindle of this machine is mounted horizontally. This

machine has the following important parts.
L

1) Base: It is a heavy casting made of grey cast iron. It

A

supports all other parts of the machine.

K

2) Column: A vertical hollow column is mounted on the

base. The driving mechanism for spindle and table is
placed inside the column. The column has guide ways on
the top and its front face.
3) Knee: The knee is mounted on the column. It slides up and
down along the guide ways provided at the front face of the
column. The knee can be moved vertically by rotating the
elevating screw fitted on the base. Horizontal dove tail guide
ways are provided on the top of the knee. These guide ways
are perpendicular to the column.
,
3.7
 4) Saddle: The saddle is mounted on the guide ways of the
knee. The saddle can be moved towards or away from the
column. This provides cross feed to the work piece. It has
horizontal guide ways parallel to the front face of the
column.
5) Table: The table is mounted on the guide ways of the
saddle. The longitudinal feed of the table is perpendicular
to the spindle axis. The table has T-slots on its top surface
to clamp the work piece.
6) Spindle: The spindle is mounted at the front face of the
column. The font end of the spindle is called nose. The nose

M
just projects from the column. It has a hole with Morse
A
taper. Arbor or tapered shank cutters can be fitted in to this
G
hole. The spindle is rotated by an electric motor through
PA

belts and gears at various speeds.

IP

7) Over arm: The over arm is mounted in the guide ways on

the top of the column. The arbor is supported by the yoke
TH

inserted in to the over arm.

PA

3.4.2 VERTICAL MILLING MACHINE

Description
L

The spindle of this machine is mounted vertically. This

A

machine has the following important parts.

K

1) Column: A vertical column is mounted on the base. The

driving mechanism for spindle and table is placed inside
the column. The column has guide ways on the top and its
front face.
2) Knee: A knee is fitted on the vertical guide ways provided
in the front face of the column. The knee has horizontal
guide ways on its top surface.
3) Saddle: The saddle slides on the horizontal guide ways
towards or away from the column. This movement is
perpendicular to the spindle axis.
,
3.8
 4) Table: The table is mounted in the guide ways provided
on the top of the spindle. The table moves longitudinally
along these guide ways. The table movement is also
perpendicular to the spindle axis.
5) Spindle: The spindle head is mounted on the top of the
column with a swivel base. So it can be tilted to required
angle for machining angular surfaces. End milling cutters
and face milling cutters are fitted in the spindle.

Swivel base

M
Head

A
G
Spindle
PA

Cutter
Table
IP

Saddle
TH

Column
PA

Knee

Handle for knee

L
A
K

Base

Fig.3.4 Vertical milling machine

Principle of operation milling machine
The milling cutter is fitted in the spindle nose or in the
arbor. The work piece is held on the table by suitable work
holding device. The knee is moved vertically by rotating the
elevating screw so that the cutter touches the work piece surface.
The cutter is rotated with proper cutting speed.

,
3.9
 The work piece is fed against the cutter slowly. The feed
may be given longitudinally, crosswise or vertically. In some
milling machines, the work piece may be fed at an [Link]
rotating cutter removes the metal from the work piece in the
form of chips.

3.5 COMPUTER NUMERICAL CONTROL (CNC)

Computer numerical control (CNC) is defined as a
numerical control (NC) system that utilizes a dedicated
microcomputer to perform some or all of the basic numerical
control functions. Numerical control (NC) system is a method of

M
automation in which various functions of machine tools are

A
controlled by letters, numbers and symbols.G
Components of CNC system
PA

A CNC system consists of the following three basic

components.
IP

1) Program of instructions
TH

2) Machine Control Unit (MCU)

PA

3) Machine tool
L

Program Machine
A

control unit
K

Machine tool
Fig. 3.5 Components of CNC system

1) Program of instructions
In machine tool applications, the program of instruction is
called a part program, and the person who prepares the program
is called a part programmer. The part program consists of
instructions written in the numerical codes that constitutes the
basic operations to be carried out in machining of the part.

,
3.10
 These instructions include the positions of cutting tool
relative to the worktable, spindle speed, feed rate, cutting tool
selection, and other functions. The program is entered into MCU
through any one of the part programming methods.
2) Machine Control Unit
Machine control unit consists of the electronics and
hardwares that read and interpret the part program and convert
it into mechanical actions of the machine tool.
CNC controller unit includes the following elements.
Central processing unit

M
Memory

A
Input / Output interface G
Controls for machine tool axes and spindle speed.
PA

Programmable logic controller

3) Machine tool
IP

Machine tool is the part of the CNC system that performs

TH

useful work. It accomplishes the processing steps to transform the

starting work piece into a completed part. Typically a CNC
PA

machine tool consists of the work table and spindle as well as the
motors and controls necessary to drive them. It also includes the
L

cutting tools, work fixtures, and other auxiliary equipment needed

A

in the machining operation.

K

Working of CNC system

The part program is entered into the machine control unit. The
controller translates these numerical codes into the machine
actuation details, which are then used to control the individual
machine functions such as the movement of the axes.
Each of the machine axes is connected to a servomotor
which works under the control of the MCU. The
movement of the cutting tool with respect to the work
piece is given in terms of the coordinates. These are used

,
3.11
 to control the motion of the servomotor which drives the
individual axes.
Most of the CNC tools are controlled with a feed back
control system. The feed back information is provided to
the machine control unit to ensure that the programmed
instructions are accurately carried out.

Features of CNC machines

Storage of part programs into computer memory.
Automatic determination of tool path.
Simultaneous execution of various functions.

M
Automatic tool changing.

A
Automatic work piece positioning.
G
Automatic checking of finished work piece dimensions.
PA

High speed cutting of complex contours.

Background feed back communication for corrective
IP

measures.
Absolute position detection.
TH

Tool breakage detection and recovery.

PA

Applications of CNC
1) Machine tool applications
L

CNC lathe
A

CNC boring mill

K

CNC drill press

CNC milling machine
CNC cylindrical grinder
2) Metal working applications
Punch presses for sheet metal hole punching
Presses for sheet metal bending
Welding machines
Flame cutting machines
Laser cutting machines
Tube bending machines
,
3.12
3) Other CNC applications
Assembly machines
Electrical wire wrap machines
Component insertion machines
Inspection machines
Coordinate measuring machines
Cloth cutting machines
Automated knitting machines
Automated riveting machines

REVIEW QUESTIONS

M
A
1) Define machine tool. List out the common machine tools.
G
2) What is lathe? Explain the principle of lathe.
PA

3) Describe the various parts of a lathe with a neat sketch.

4) List out the types of drilling machines.
IP

5) Explain the construction and principle of operation of

TH

upright drilling machine with a neat sketch.

6) Explain the principle of milling.
PA

7) With a neat sketch, describe the construction and working

of operation of horizontal milling machine.
L

8) Explain the construction and principle of operation of

A

vertical milling machine with a neat sketch.

K

9) Define CNC. List out the features in a CNC system.

10) Describe the components and working principle of a CNC
system.
11) List out the applications of CNC system.

,
3.13
 Unit – IV
POWER TRANSMISSION DRIVES
AND LUBRICATION
4.1 BELT DRIVES
Belt drives are used for transmitting power from one shaft
to another shaft. The belts are running over the pulleys. The
pulley which is keyed to the rotating shaft is known as driver
pulley. The pulley which is keyed to the shaft which is to be
rotated is known as driven pulley or follower pulley.

M
When the driver pulley rotates, it carries the belt due to the
friction between the belt and the pulley. The belt, in turn, carries
the driven pulley which also rotates. A
G
PA

4.1.1 TYPES OF BELT DRIVES

The belt drives are classified as follows:
IP

1) Flat belt drive

TH

2) V–belt drive
3) Circular belt or rope drive
PA

1) Flat belt drive

Leather or rubberized fabric is used for making flat belts.
L

The cross section of the flat belt is rectangular. They are used
A

where a medium amount of power is to be transmitted from one

K

pulley to another pulley. They connect the pulleys, which are at

a distance up to 10m.
The important types of flat belt drives are :
(i) Open belt drive
(ii) Cross belt drive
(iii) Compound belt drive
(i) Open belt drive
When the two pulleys are arranged in parallel and both are
to be rotated in same direction, an open belt drive is used.

,
4.1
 Driver Slack side
Driven

Belt

Tight side

Fig.4.1 Open belt drive

The driver pulley pulls the belt from lower side and
delivers it to the upper side. Hence the tension in the lower side
of the belt will be more than the tension in the upper side. The

M
lower side belt is known as tight side and the upper side belt is
known as slack side.
A
G
(ii) Cross belt drive
PA

Slack side
Driven
IP
TH

Belt
PA

Tight side
Driver
L

Fig.4.2 Cross belt drive

A
K

The cross belt drive is used when the shafts are arranged
in parallel and rotate in the opposite direction.

iii) Compound belt drive

Driver Driven
pulley pulley

Belt

Fig.4.3 Compound belt drive

,
4.2
 When power is to be transmitted from one shaft to another
shaft through a number of pulleys, then a compound belt drive
is used.

Applications of flat belt drive

Agricultural machines
Machine tools
Flour mills
Generators
Fans
Blowers

M
Pump

A
Textile machineries G
Sugar mills, etc.
PA

Advantages of flat belt drive

1) Simple construction.
IP

2) Cost of the belt is less.

TH

3) Runs smoothly.
4) Suitable for transmitting power between two shafts
PA

arranged in any position.

5) Transmits power over considerable distance between
L

driver and driven.

A
K

Disadvantages
1) Slip of the belt may occur
2) Requires comparatively large size.
3) Life of the belt is short.

2) V–belt drives
The cross section of V–belt is trapezoidal. They are used
when large amount of power is to be transmitted from one pulley
to another. They are used to connect pulleys which are very near
to each other. The V–belts are made longitudinal textile fibre
impregnated and covered with rubber.
,
4.3
 V - Belt
Cords
Fabric
Rubber
Pulley Fabric and
rubber cover
Cross section of V - belt
Fig.4.4 V–belt drive
Applications
Agriculture machines

M
Generators
Machine tools
A
G
Fans
PA

Blowers
Pumps
IP

Compressors
TH

Textile machineries, etc.

Advantages of V–belt drive
PA

1) Suitable for transmission of power for short centre distance

2) Space required for the drive is less.
L

3) Less vibration and noise.

A

4) Transmits more power.

K

5) Slip of the belt will not occur.

6) Replacement and maintenance is easy.
7) V–belts are made endless. Hence there is no joint trouble.
Disadvantages
1) Cost of the belt is more
2) V–belts are not durable as flat belts.
3) Construction of pulleys for v–belts is more complicated
than flat belts.
4) V–belts cannot be used to transmit power for long distance.
5) Belt wears out quickly.
,
4.4
3) Circular belt or rope drive
Rope

Pulley

Fig.4.5 Rope drive

The cross section of the rope is circular. They are used

M
when a large amount of power is to be transmitted from one
pulley to another pulley. The rope drive is preferred when the
A
centre distance between the pulleys are more than 5 metre.
G
PA

The ropes are made from cotton, manila, hemp or wire.

Rope drives can be effectively used when there is misalignment
IP

between the pulleys, fluctuating temperature and humidity.

TH

Applications
Hand operated hoisting machines.
PA

Cranes, conveyors, elevators, etc.

Hoisting purposes in mines and quarries.
L

Textile industries.
A

Tram ways, rope cars, etc.

K

Advantages of rope drives

1) Weight of the belt is less.
2) Cost of the belt is low.
3) More durable and reliable as compared with other belts.
4) Frictional grip is more.
5) Withstands shock load.
6) Large amount of power can be transmitted.
7) Suitable for transmission of power for large distances.
Disadvantages
1) Not suitable to transmit power for short distance.
,
4.5
4.2 CHAIN DRIVES
Chain link

Smaller sprocket

Larger sprocket

Fig.4.6 Chain drive

When the power is transmitted over a shorter distance,
chain drives are used. A belt or a rope drive does not give a

M
constant velocity ratio due to slip. In order to avoid slipping and
A
to have a constant velocity ratio, steel chains are used.
G
PA

The chains are made up of a number of rigid links. The links

hinged together by pin joints in order to provide the necessary
IP

flexibility for warping round the driving and driven wheels.

TH

The wheels over which the chains running are called

sprockets. The sprocket has projected teeth that fit into the
PA

recesses in the chain and they are generally keyed to the shafts.
Applications of chain drives
L

Bicycles
A

Motor vehicles
K

Agricultural machineries
Conveyors
Hoists
Rolling mills
Road rollers, etc.
Advantages of chain drive
1) Positive non–slip drive
2) Compact and occupies less space.
3) No initial tension is required.
4) Transmits large amount of power.
,
4.6
 5) Transmission efficiency is high.
6) Absorbs shocks.
7) Useful for low speed and high torque transmission.
8) More durable.
Disadvantages of chain drive
1) Production cost is comparatively high.
2) Lubrication is necessary for better efficiency.
3) Heavier as compared to the belts.
4) Gradual stretching of chain on use leads to velocity
fluctuations.

M
4.3 GEAR DRIVES

A
Gear drives are used to transmit power from one shaft to
G
another shaft where constant velocity ratio is essential. The gear
PA

drives are classified as follows:

a) According to the position of axes of shafts
IP

i) Parallel shafts drive

TH

ii) Intersecting shafts drive

iii) Non–intersecting or skew shafts drive
PA

b) According to the peripheral velocity of the gear

i) Low velocity drive ii) Medium velocity drive
L

iii) High velocity drive

A

c) According to the type of gearing

K

i) External gear drive ii) Internal gear drive

iii) Rack and pinion drive

4.11 TYPES OF GEAR DRIVES

The types of gear drives are:
1) Spur gear drive
2) Helical gear rive
3) Bevel gear drive
4) Worm and worm wheel drive
5) Rack and pinion drive

,
4.7
1) Spur gear drive

Fig.4.7 Spur gear drive

In spur gears, teeth are cut on the periphery of a cylindrical
disc at equal space parallel to the axis of the wheel. These gears

M
are used to transmit motion between two parallel shafts.

A
When the spur gears mesh internally, it is called internal
G
gears whereas if they mesh externally, they are called external
PA

gears. In case of internal gearing, they rotate in same direction

IP

whereas in internal gearing, they rotate in opposite direction.

TH

Applications of spur gear drive

1) Transmission of motion from main spindle to lead screw
PA

in lathe.
2) Head stock back gear mechanism of lathe.
3) Magnifying elements in mechanical comparators and
L
A

measuring instruments.
K

4) Gear box of automobiles.

5) Watches and clocks.
6) Gear pumps, toys, cameras and electrical appliances.
2) Helical gear drive
In helical gear, helical teeth are cut at an angle to the axis of
rotation. These gears are used to transmit motion between two
parallel or non–parallel or intersecting shafts. More power can be
transmitted by means of helical gear. Helical gears run smoothly
without noise. If double helix is provided in gears, such gears are
called herringbone gears.
,
4.8
 Helical gear Heringhone gear

Fig.4.8 Helical gear drive

Applications of helical gear drive

1) Gear box and final drive of automobiles
2) Cam shaft of I.C engines.

M
3) Timing gears in I.C engines.
4) Oil pumps.
A
G
PA

3) Bevel gear drive

IP
TH
PA
L

Fig.4.9 Bevel gear drive

A

Bevel gears are used to transmit motion between two

K

shafts, which are inclined at an angle to each other. In this gear,

the teeth are cut on the surface of a truncated cone. If two bevel
gears are symmetrical to each other and transmit motion at 90o,
such gears are called as mitre gears.
Applications of bevel gear drive
1) Hand drilling machine.
2) Differential of automobiles.
3) Drill chuck key.
4) Worktable of machine tools.

,
4.9
4) Worm and worm wheel drive

Worm

Worm
wheel

Fig.4.10 Worm and worm wheel drive

They are used to transmit motion between two shafts, which
are perpendicular to each other. Generally worm will be the driver

M
and worm wheel will be the driven. By using worm and worm
A
wheel, more power can be transmitted with high efficiency. Speed
G
can be very much reduced by using these gears.
PA

Applications of worm and worm wheel drive

IP

1) Indexing heads.
2) Final drive and steering gear box of automobiles.
TH

3) Wind shield wiper.

PA

5) Rack and pinion drive

Rack
L
A

Pinion
K

Fig.4.11 Rack and pinion drive

The rack and pinion drive is used to convert rotary motion
into linear motion and linear motion into rotary motion. Rack is
a rectangular bar on which straight teeth are cut parallel to the
axis of pinion. Pinion is a small spur gear. The rack and pinion
always used together.
,
4.10
Applications of rack and pinion drive
1) Moving the carriage in lathe
2) Movement of spindle in drilling machine
3) Movement of table in planning machine.
4) Steering gear box of automobiles.
5) Fuel injection pump of diesel engine.
Advantages of gear drives
1) Transmits motion at exact velocity ratio.
2) High efficiency.
3) Transmits a large power.

M
4) Compact layout.

A
5) No slip as in belt drives. G
6) Reliable service.
PA

Disadvantages
IP

1) Manufacturing cost of gear is more, as it requires special

equipment and tools.
TH

2) Any error in the tooth profile causes vibrations and noise

during operation.
PA

3) Any defect in one wheel damages the whole set up.

4) Maintenance cost for gear drive is more, as it requires
L

lubrication.
A

5) Backlash error may occur due to improper meshing of gears.

K

4.5 CAM DRIVE

A cam is a rotating machine element which gives
reciprocating or oscillating motion to another element
known as follower. The cam is usually rotated at uniform
speed by a shaft. The follower is moved according to the
shape of the cam. A slide is provided to guide the motion
of the follower.
The cam and follower pair is generally used to convert a
rotary motion into reciprocating motion.
,
4.11
 Based on the shape, the cams are classified as plate cam,
cylindrical cam, wedge cam, spherical cam, etc.
Based on the surface of contact, the followers are classified
as knife edge follower, roller follower, flat-faced follower,
spherical follower, radial follower, offset follower, etc.

Slide Knife edge

follower

Plate cam

M
A
G
PA
IP

Fig.4.12 Cam drive

TH

Applications of cam drive

1) Internal combustion engines
PA

2) Automatic lathes
3) Hydraulic systems
L

4) Gear cutting machines

A

5) Paper cutting and printing machines

K

6) Automatic indexing machines

7) Textile weaving machines
8) Wall clocks
9) Children toys, etc.

4.6 LUBRICANTS
The lubricants are used in bearings to reduce friction and
wear between the rubbing surfaces and to carry away the heat
generated by friction. It also protects the bearing against
corrosion.

,
4.12
 The lubricants are mainly classified as follows:
1) Solid lubricants
2) Semi–solid lubricants
3) Liquid lubricants

1) Solid lubricants
Solid lubricants are used to reduce friction where oil film
cannot be maintained because of high pressure or
temperature. They should be softer than the materials,
which is to be lubricated.
Example: Graphite, wax, mica, French chalk, etc. are the

M
commonly used solid lubricants. They can be used either

A
alone or mixed with oil. G
2) Semi–solid lubricants
PA

Semi–solid lubricants are more viscous than oils. They are

employed where slow speed and heavy pressure exist and
IP

where oil drip from the bearing is undesirable.

TH

Example: Grease is a widely used semi–solid lubricant.

Grease is employed between the surfaces that have high
PA

bearing loads and high operating temperatures. Grease

forms a seal to keep dirt or any other foreign substance.
L
A

3) Liquid lubricants
K

The liquid lubricants are preferred where they may be

retained.
Example: Mineral oils and synthetic oils are the
commonly used liquid lubricants. Mineral oil is derived
from crude petroleum by fractional distillation. Synthetic
oil is derived from animals and seeds of vegetables.
Among these, mineral oil is most widely used because of
their low cost and stability.

,
4.13
4.7 PURPOSE OF LUBRICATION
1) To reduce friction between moving parts
2) To reduce wear and tear of the bearing surfaces
3) To dissipate the heat generated from the moving parts
4) To provide cushioning effect against the shock
5) To reduce the noise while the moving parts rub against
each other
6) To reduce the corrosion and erosion of moving parts
7) To protect the bearing surfaces from water, dirt, etc.
8) To provide cooling effect to the rubbing parts

M
4.8 PROPERTIES OF LUBRICANTS

A
The important properties of lubricants are given below.
G
1) Viscosity: Viscosity is the measure of degree of fluidity of
PA

an oil by which it can withstand high pressure or load

without squeezing out form the bearing surface. Viscosity
IP

of the oil decreases with the increase in temperature.

TH

Viscosity of the lubricating oil should not fall below a

certain specified value at highest operating temperature of
PA

the bearing.
2) Oiliness: It is the ability of an oil to spread and adhere
L

itself firmly with the bearing surfaces. Oiliness of the

A

lubricating oil should be high for better lubrication.

K

3) Flash point: Flash point of oil is the lowest temperature at

which it gives off enough vapour so that a momentary
flash is obtained when a flame is brought near the oil
surface. The flash point of the lubricant oil should be
higher than the operating temperature of the bearing.
4) Fire point: Fire point of oil is the lowest temperature at
which it catches fire and burns continuously. Fire point is
always greater than the flash point.

,
4.14
 5) Volatility: An oil may evaporate, when it is exposed to a
high temperature for long time. This property is known as
volatility. The lubricating oil should have low volatility at
the operating temperature of the bearing.
6) Demulsibillity (Water separation): The property of
resisting emulsification is known as demulsibility. The
lubricating oil should not form an emulsion when brought
in contact with water.
7) Foaming: It is the condition in which minute air bubbles are
held in the oil. This will reduce mass flow of oil and hence
the lubricating oil should be free from foaming trouble.

M
A
8) Corrosion resistance: The lubricating oil should prevent
G
corrosion and it should not contain sulphur.
PA

9) Stability: It is an ability of an oil to resist oxidation.

Lubricating oil should have high stability.
IP

10) Film strength: It is the property of the lubricating oil due

TH

to which the oil retains a thin film between the bearing

surfaces even at high speed and load. The film does not
PA

break and the two surfaces do not come in direct contact.

4.9 METHODS OF LUBRICATION

L
A

The following are commonly used methods of lubrication.

K

1) Ring oiler lubrication

Ring oiler lubrication is a type of splash lubrication. This
method works on the principle of adhesion. It is used for
lubricating horizontal shaft. In this method, a brass ring is placed
loosely on the shaft and passes below the bearing. The oil ring is
larger in diameter than the shaft. The bottom portion of the ring is
dipped into the oil sump.
When the shaft rotates, the ring also rotates loosely. The
oil adhering to the ring is brought up and fed into the bearing.
Spreader grooves are provided in the bearing to distribute the oil
,
4.15
along the length of the bearing. Thus, the bearing is lubricated.
Finally, the oil drains back to the oil sump. When the shaft is
longer, number of oil rings are provided at specified distance
along its length.
Filling cap
Casing
Bearing Shaft Bearing
Shaft
Oil ring

Oil ring

M
A
Oil G
Fig.4.13 Ring oiler lubrication
PA

Applications
IP

This method is used for lubricating head stock of the lathe,

stationary equipments like compressors, generators, motors, etc.
TH

2) Drip feed lubrication (or) Sight feed lubrication

PA

Adjusting screw
L
A
K

Oil cup

Valve

Sight glass

Fig.4.14 Drip feed lubrication

,
4.16
 Drip feed lubrication is a type of gravity feed lubrication
system. In this method, an oil cup with central hole is screwed into
the bearing housing. When the cup is filled with lubricating oil, the
oil flows into the shaft surface through the hole by gravity. The
flow of oil can be observed through the glass and is controlled by
adjusting the position of the valve.
Applications
This system is used for lubricating external moving parts such
as bearings, cross head, crank pins of internal combustion engines.
3) Grease cup lubrication

M
Cup

A
G
PA

Grease
IP
TH

Fig.4.15 Grease cup lubrication

Grease cup lubrication is a type of force feed lubrication
PA

system. In this method, a grease cup made of two parts is used.

The lower part with central hole is threaded into the oil hole in the
L

bearing housing. The upper cup is filled with grease and screwed
A

with the lower part. This causes a pressure on the grease.

K

When the shaft rotates, the grease will melt due to the heat
generated on the bearing surface. The grease will flow into the
bearing surface through the oil hole. The upper cup is tightened at
regular interval in order to maintain a force on the grease. When
the level of the grease goes down, the cup is unscrewed and filled
with sufficient grease. In spring type grease cup method, a
compressive spring is used to maintain the force on the grease.
Applications
Grease cup lubrication is used in tractors, lawnmowers,
industrial plant equipment, trucks, etc.
,
4.17
 REVIEW QUESTIONS

1) What is belt drive? List out its types.

2) Describe the three types of flat belt drive. State its
applications.
3) List out the advantages and disadvantages of flat belt drives.
4) Write short notes on V-belt drive. List out its applications,
advantages and disadvantages.
5) Describe rope drive with a sketch. Give its applications,
merits and demerits.
6) Explain chain drive with a sketch. List out its applications,

M
advantages and disadvantages.

A
7) What is gear drive? Name the types of gear drives.
G
8) Classify gear drives.
PA

9) Explain spur gear drive with a sketch. State its applications.

IP

10) Write short notes on helical gear drive. Give its applications.
11) Describe bevel gear drive with a sketch. List out its
TH

applications.
PA

12) With a sketch, explain worm and worm wheel gear drive.
Give its applications.
L

13) Explain rack and pinion gear drive with sketch. State its
A

applications.
K

14) Write short notes on cam drive. Mention its applications.

15) Briefly explain the types of lubricants. Give examples.
16) What are the purposes of lubrication?
17) List and explain the properties of lubricants.
18) Explain the ring oiler lubrication method with a sketch.
19) With a sketch, explain the drip feed lubrication method.
20) Explain the grease cup lubrication method with a sketch.

,
4.18
 Unit – V
FUNDAMENTALS OF
HEAT POWER ENGINEERING
5.1 HEAT
The heat is defined as the energy transferred across the
boundary of a system due to the temperature difference between
the system and the surroundings. It is represented by the symbol Q.
In SI system, the unit of heat is joule (J) or kilo-joule (kJ).
If m kg of substance is heated from an initial temperature

M
𝑇1 to a final temperature 𝑇2 , then the heat transfer is given by,
𝑸 = 𝒎 𝑪 (𝑻𝟐 − 𝑻𝟏 ) A
G
PA

where, C = specific heat of the substance (J/kg.K)

If Q is positive, heat is supplied to the system (heating
IP

process)
TH

If Q is negative, heat is rejected from the system (

Cooling process)
PA

5.2 MODES OF HEAT TRANSFER

L

The fundamental modes of heat transfer are:

A

1) Conduction
K

2) Convection
3) Radiation

1) Conduction
Conduction is the transfer of heat energy by microscopic
diffusion and collisions of particles within a body due to a
temperature gradient. It is also defined as the transfer of energy
through the direct physical contact of matter or particles.
Heat is transferred by conduction when adjacent atoms
vibrate against one another

,
5.1
 Conduction takes place in solids, liquids and gases.
Conduction is greater in solids Liquids and gases are less
conductive.
Examples of conduction
 Heat flow from the hot to cold fluid in a heat exchanger
 Cooling of an electric bulb by the surrounding
atmosphere
 Heating and cooling of the water of an I.C engine.
 Cooling of castings in a foundry.
 Heat transfer from our hands to ice cube
 Heat transfer from hot tea cup to our hands

M
 Ironing of clothes

A
G
2) Convection
PA

Convection is the transfer of thermal energy from one

place to another by the movement of liquid or gases.
IP

Convection is usually the dominant form of heat transfer

in liquids and gases.
TH

The two types of convections are free convection and

PA

forced convection.
Examples of convection:
L

 The upward flow of air due to a fire or hot object

A

 The circulation of water in a pot that is heated from bottom.

K

 Cooling of billets in the atmosphere.

 Flow of water in condenser tubes
 Fluid passing through the tubes of a heat exchanger
 Cooling of internal combustion engines

3) Radiation
Thermal radiation is electromagnetic radiation generated
by the thermal motion of charged particles in matter.
All matter with a temperature greater than absolute zero
emits thermal radiation.

,
5.2
 Examples of thermal radiation:
 Visible light from sun
 Infrared light emitted by an incandescent light bulb
 Infrared radiation emitted by animals

5.3 INTERNAL COMBUSTION (I.C) ENGINES

A machine which converts heat energy into mechanical
work is known as heat engine. Internal combustion (I.C) engine
is a heat engine in which combustion of fuel takes place inside
the engine cylinder.
Example: Petrol engine, diesel engine, gas engine, gas

M
turbine, etc.

A
G
5.3.1 CLASSIFICATION OF I.C. ENGINES
PA

Internal combustion engines may be classified based on

the following:
IP

1) Type of fuel used

TH

(a) Petrol engines (b) Diesel engines (c) Gas engines

PA

2) Number of strokes per cycle

(a) Four stroke engine (b) Two stroke engine
L

3) Method of ignition
A

(a) Spark Ignition (S.I) engines

K

(b) Compression Ignition (C.I) engines

4) Arrangement of cylinders
(a) Vertical engines (b) Horizontal engines
(c) V-type engines (d) In-line engines
(e) Radial engines

5) Cooling system used

(a) Air cooled engines (b) Water cooled engines

,
5.3
6) Number of cylinders
(a) Single cylinder engines (b) Multi-cylinder engines

7) Speed of the engine

a) Low speed engines b) Medium speed engines
c) High speed engine

5.3.2 FOUR STROKE PETROL ENGINE

A four stroke petrol engine requires four strokes of piston
to complete one cycle of operation. In petrol engines, as the air
fuel mixture is ignited by a spark plug, it is also known as spark
ignition engines.

M
A
Air + Fuel
mixture
G
Spark plug
PA

Inlet valve
Piston
Connecting rod
IP
TH

Crank shaft Cylinder

PA

Crank

1) Suction stroke 2) Compression stroke

L
A
K

Spark
Exhaust valve

3) Power stroke 4) Exhaust stroke

Fig.5.1 Four stroke petrol engine

,
5.4
Construction
The engine contains a piston, which reciprocates inside the
cylinder. The piston is connected to the crank shaft by means of
connecting rod and crank. The inlet and outlet valves are
mounted on the cylinder head. A spark plug is also provided on
the cylinder head for spark ignition.

Working
The events in a four stroke cycle petrol engine are as follows.
1) Suction or charging stroke
In this stroke, the required air–fuel mixture called as

M
charge is sucked into the engine cylinder. During this stroke,

A
piston moves down from Top Dead Centre (TDC) to Bottom
G
Dead Centre (BDC). Due to the downward movement of the
PA

piston, the pressure inside the cylinder is reduced below the

atmospheric pressure. Now inlet valve opens and fresh air–fuel
IP

mixture is sucked into the cylinder through the inlet valve.

TH

Exhaust valve remains closed during this stroke.

2) Compression stroke
PA

In this stroke, the air–fuel mixture inside the cylinder is

compressed. During this stroke, the piston moves up from BDC
L

to TDC and both the inlet and outlet valves are kept closed. Due
A

to the upward movement of the piston, the air–fuel mixture in

K

the cylinder is compressed. As a result of compression, the

pressure and temperature of air–fuel mixture increases
considerably. This completes one revolution of crank shaft.

Ignition: When the piston reaches near TDC, an electric

spark is produced by the spark plug. The compressed air–fuel
mixture is ignited by the spark. It results in a sudden increase of
temperature and pressure of combustion products. However, the
volume remains constant during combustion.

,
5.5
3) Expansion stroke or working stroke or power stroke
In this stroke, the heat energy is converted into useful
mechanical work. The burning gases expand rapidly. A force is
exerted on the piston due to the high pressure and expansion of
hot gases. Now the piston is pushed downward from TDC to
BDC. The movement of the piston is converted into rotary
motion of the crank shaft through connecting rod. Thus, the heat
energy is transformed into useful mechanical work. Both inlet
and exhaust valves are closed during this stroke.

4) Exhaust stroke
In this stroke, the burnt gases are exhausted from the cylinder.

M
Now the exhaust valve is opened. The piston moves upward from
A
BDC to TDC. This movement of piston pushes out the burnt gases
G
to the atmosphere through exhaust valve. During this stroke, the inlet
PA

valve remains closed. This completes one cycle and the cylinder is
ready to suck air–fuel mixture to start a new cycle.
IP
TH

Thus in a four stroke engine, there is only one power stroke

and three idle strokes. The power stroke supplies the required
PA

momentum to carry out all other strokes. Thus the engine is kept
running
L
A

5.3.3 FOUR STROKE DIESEL ENGINE

K

A four stroke diesel engine requires four strokes of piston

to complete one cycle of operation. In diesel engines, as the air–
fuel mixture is ignited due to the temperature developed by the
compression, it is also known as compression ignition engines.

Construction
This engine contains a piston, which reciprocates inside
the cylinder. The piston is connected to the crank shaft by means
of connecting rod and crank. The inlet and outlet valves are
mounted on the cylinder head. A fuel injector is also provided
on the cylinder head for injection of fuel.
,
5.6
 Air

Inlet valve Fuel Injector

Piston
Connecting rod

Crank shaft Cylinder

Crank

1) Suction stroke 2) Compression stroke

M
Diesel
Exhaust valve

A
G
PA
IP
TH

3) Power stroke 4) Exhaust stroke

PA

Fig.5.2 Four stroke diesel engine

L

Working
A

The events in four stroke cycle diesel engine are as

K

follows.

1) Suction stroke
In this stroke, the air is sucked into the engine cylinder.
During this stroke, piston moves down from Top Dead Centre
(TDC) to Bottom Dead Centre (BDC). Due to the downward
movement of the piston, the pressure inside the cylinder is reduced
below the atmospheric pressure. Now the air from the atmosphere
is sucked into the cylinder through the inlet valve after filtering.
The exhaust valve remains closed during this stroke.

,
5.7
2) Compression stroke
In this stroke, the air inside the cylinder is compressed.
During this stroke, the piston moves up from BDC to TDC and
both the inlet and outlet valves are kept closed. Due to the
upward movement of the piston, the air in the cylinder is
compressed. As a result of compression, the pressure and
temperature of air increases considerably. This completes one
revolution of crank shaft.

Ignition: When the piston reaches near TDC, the fuel is

injected into the cylinder in the form of fine spray with the help

M
of fuel injector. Due to high pressure and temperature of
compressed air, the air–fuel mixture is ignited. It results in a
A
sudden increase of temperature and pressure of combustion
G
products. However, the volume remains constant during
PA

combustion.
IP

3) Expansion stroke or working stroke or power stroke

TH

In this stroke, the heat energy is converted into useful

mechanical work. The burning gases expand rapidly. A force is
PA

exerted on the piston due to the high pressure and expansion of

hot gases. Now the piston is pushed downward from TDC to
L

BDC. The movement of the piston is converted into rotary

A

motion of the crank shaft through connecting rod. Thus, the heat
K

energy is transformed into useful mechanical work. Both inlet

and exhaust valves are closed during this stroke.

4) Exhaust stroke
In this stroke, the burnt gases are exhausted from the
cylinder. Now the exhaust valve is opened. The piston moves
upward from BDC to TDC. This movement of piston pushes out
the burnt gases to the atmosphere through exhaust valve. During
this stroke, the inlet valve remains closed. This completes one
cycle and the cylinder is ready to suck air to start a new cycle.

,
5.8
 Thus in a four stroke engine, there is only one power stroke
and three idle strokes. The power stroke supplies the required
momentum to carry out all other strokes. Thus the engine is kept
running.

5.3.4 COMPARISON OF PETROL ENGINE AND DIESEL ENGINE

Petrol engines Diesel engines

1) Air–fuel mixture is sucked Air alone is sucked into the
into the cylinder during cylinder during suction
suction stroke. stroke.
2) Petrol engine operates with Diesel engine operates with

M
low pressure and high pressure and
temperature.
A
temperature.
G
3) Carburetor and spark plugs Fuel injection pump and
PA

are provided. injectors are provided.

4) Ignition of air–fuel mixture Ignition of air–fuel mixture
IP

takes place by an electric takes place due to the heat

TH

spark produced by the spark developed by the

plug. compression of air.
PA

5) Operating speed is more. Operating speed is less.

6) Starting is easy. Starting is not so easy.
L

7) These engines produce less These engines produce more

A

noise. noise.
K

8) The cost of petrol is more. The cost of diesel is less than

petrol.
9) Petrol engines are widely Diesel engines are widely
used in light vehicles, used in heavy vehicles such
automobiles, airplanes, etc. as buses, lorries, trucks,
tractors, etc.

,
5.9
5.4 BATTERY ELECTRIC VEHICLE (BEV)

Reduction
Gear

Electric
Motor

Inverter

M
Battery

A
G
PA
IP
TH

Fig.5.3 Battery Electric Vehicle (BEV)

PA

Battery Electric Vehicle (BEV) is a fully electric vehicle

with rechargeable batteries. The electricity required to drive the
vehicle is stored in a large battery pack. The battery can be
L

charged by plugging into the electricity grid.

A
K

Main components of BEV:

Battery : Rechargeable lithium-iron battery to store
electrical energy
Inverter: Converts DC power from the battery to AC
power.
Motor : Converts the electrical energy into mechanical
energy.
Controller : Controls the speed of motor
Reduction gear : Connects the motor with the wheels.

,
5.10
Working Principles of BEV:
The DC power from the battery is converted to AC by the
inverter. When the accelerator is pressed, a signal is sent to the
controller. The controller adjusts the speed of the motor by
changing the frequency of the AC power from the inverter. The
motor rotates the wheels through a reduction gear. If the brakes
are pressed, or the electric vehicle is decelerating, the motor
becomes an alternator and produces electric power. The electric
power is sent back to the battery.

Examples of BEV:

M
BEVs include motorcycles, bicycles, scooters, skateboards,

A
railcars, watercraft, forklifts, buses, trucks, and cars. The
G
commonly known battery electric cars are:
PA

Hyundai Kona
Tata Tiago EV
IP

Tata Tigor EV
TH

Mahindra XUV300 EV
Mahindra E Verito
PA

MG ZS EV
Mercedes-Benz EQB
L

BYD Atto 3
A

Kia EV6
K

BMW iX

Advantages of battery electric vehicle

1) Lower running cost
2) Low maintenance cost
3) Tax and financial benefits
4) Better performance
5) Zero tailpipe emissions
6) Easy to drive

,
5.11
 7) Quiet in operation
8) Convenience of charging at home
9) No noise pollution
Disadvantages of battery electric vehicle
1) High initial purchase cost
2) Replacing the batteries is expensive
3) Limited battery range
4) Long charging time
5) Less number of charging stations
6) Low top speeds

M
A
5.5 STEAM POWER PLANT G
Steam power plant is a type of power station in which heat
PA

energy is converted into electrical energy. The heat is produced

by burning coal. The heat is used to boil water in a large boiler
IP

to produce high pressure steam. The steam drives a steam turbine

connected to an electrical generator.
TH

5.5.1 LAYOUT OF STEAM POWER PLANT

PA

The working of a steam power plant can be explained in

four circuits as follows :
L
A

1) Coal and ash circuit

K

The coal obtained from coal mines is sized by crushers and

stored in storage yard. Then the coal is transferred to the boiler
furnace and burnt. The ash formed is transferred to ash storage.

2) Water and steam circuit

The feed water is preheated by the flue gases in the
economiser. The preheated water is supplied to the boiler and
converted into steam. The steam is superheated by the flue gases
in superheater. The superheated steam is then expanded in a
turbine to do work. The turbine drives a generator to produce
electric power.
,
5.12
,
Atmospheric air

Flue gas
Air Dust
K preheater collector
Pre-heated air
A Flue gas
L Chimney
Steam S.H. Steam
PA Super heater

Boiler Turbine
Coal
TH
Generator

Flue gas
IP Exhaust
steam Cooling
tower
PA
Ash Hot water
Economiser
G Condenser
storage
A

Fig.5.4 Layout of steam power plant

M
Feed pump Cold water
Feed water
Pump

5.13
3) Air and flue gas circuit
Atmospheric air is passed through air preheater. The
preheated air is supplied to the furnace to assist the combustion
of fuel. Flue gases are formed due to this combustion. The flue
gas is passed over superheater tubes. Then it is passed through
economiser to heat the feed water. After that, it is passed
through air preheater to preheat the incoming air. Finally it is
exhausted to the atmosphere through chimney.

4) Cooling water circuit

Cold water is circulated through the condenser. The

M
expanded steam from turbine is condensed into water and
recirculated as feed water. The hot circulating water is cooled in
a cooling tower and is recirculated. A
G
PA

Advantages of steam power plant

1) The unit capacity of the plant is more.
IP

2) The plant life is more as compared to other plants.

TH

3) Initial cost is less than other plants.

4) Repair and maintenance cost is comparatively low.
PA

5) Suitable for varying load conditions.

6) No transmission losses.
L

7) Skilled operators are not required.

A
K

Disadvantages of steam power plant

1) Efficiency is comparatively less.
2) More space is required.
3) More cooling water is required.
4) Coal handling and storage costs are more.
5) Ash handling is difficult.
6) Labour requirement is more.

,
5.14
5.6 NUCLEAR POWER PLANT
The main components of a nuclear power plant are shown
in the figure. It consists of the following :
1) Nuclear reactor 2) Steam generator 3) Steam turbine
4) Coolant pump 5) Feed pump 6) Steam condenser
7) Electric generator

Hot coolant Steam

Turbine
Generator
Thermal
shielding Exhaust

M
steam
Steam
generator
A Condenser
G
PA

Reactor Water
core
IP
TH

Coolant Feed pump

pump
Concrete
PA

shielding
Fig.5.5 Nuclear power plant
Working
L

In nuclear reactor, a large amount of heat is produced by

A

the nuclear fission of the fuel. This heat is absorbed by the

K

coolant circulating through the reactor core. The hot coolant then
flows through the tubes of steam generator. The circulating feed
water in steam generator is converted into steam by absorbing
the heat from hot coolant.
The steam leaving the steam generator enters into a steam
turbine. Work is done by the expansion of steam in the turbine.
The generator coupled to the turbine produces electric power. The
exhaust steam from the turbine flows to the condenser. A coolant
pump is provided to circulate coolant. A feed pump is provided to
circulate feed water.

,
5.15
Advantages of nuclear power plants
1) Space requirement is less.
2) Very less fuel consumption.
3) Fuel transportation cost is low.
4) Plant operation is not affected by bad weather condition.
5) Conservation of fossil fuels for other needs.
6) Produces more power.
7) Operating cost is low.
8) Less quantity of water is required.

Disadvantages

M
1) Initial cost is high.
2) High maintenance cost. A
G
PA

3) Not suitable for varying load conditions.

4) Radio-active wastes are harmful to health.
IP

5) Skilled operators are required.

TH

5.7 SOLAR POWER PLANT

PA

Solar panels
L
A
K

Inverter Battery DC
AC

Home
Appliances

Fig.5.6 Solar power plant

,
5.16
 A solar power plant is based on the conversion of sunlight
into electricity using photovoltaics (PV). A photovoltaic system
consists of solar panels, each comprising a number of solar cells.
A solar cell is a device that converts light into electric current
using the photovoltaic effect. The photovoltaic effect is the
generation of electric current in a material when exposed to light.
Working
The main components of a solar power plant include:
1) Solar panels
2) Batteries
3) Inverter

M
The solar panels capture the solar energy and convert the
A
energy to DC (Direct Current) power. The solar panels are wired
G
with a solar charge controller to regulate the voltage of generated
PA

DC. This regulated DC is stored in the battery bank wired with

the solar charge controller.
IP

The stored DC power is converted into AC (Alternating

TH

Current) using an inverter. The AC is used to power the home

appliances. The battery bank will allow excess solar energy to
PA

be stored and used later on when required.

Advantages of solar power plant
L
A

1) Reduction in electricity cost

K

2) One time investment and free power for life

3) Eco friendly method of power production
4) Conservation of fossil fuels for other uses.
5) Cost effective method
6) Easy to install
7) Low maintenance cost
Disadvantages
1) Initial investment is high
2) Required shadow free area for installation
3) Regular maintenance is needed

,
5.17
5.8 WINDMILL
A windmill converts the kinetic energy of moving mass of
air into mechanical energy. This mechanical energy can be used
to drive a machine or to drive a generator. The windmills are
classified as: (i) horizontal axis windmill and (ii) vertical axis
windmill.
1) Horizontal axis windmill

Rotor blades
Rotor shaft

M
Generator Gear box

A
G
PA
IP

Tower
TH
PA
L
A
K

Fig.5.7 Horizontal axis windmill

A horizontal axis windmill is a type of windmill in which
the axis of rotation of the rotor is horizontal to the ground. The
main components of a horizontal axis windmill are:
Rotor: It consists of the blades and the horizontal shaft
Gearbox: It connects the shaft and the generator.
,
5.18
 Generator: It converts the mechanical energy of the rotor
into electrical energy.

The components are mounted on a bed plate on the top of

the tower. The blades of windmill are shaped like airfoils, which
create a pressure difference between their upper and lower
surfaces when the wind blows. This pressure difference causes
the blades to rotate.
The rotor shaft attached with the blades is rotated. The
rotor shaft drives a special type AC generator. The AC output is
directly fed to the AC mains. To overcome the difficulties during

M
low wind conditions, an anti-reverse device is used.

A
G
2) Vertical axis windmill
PA
IP
TH
PA

Rotor blades
L
A
K

Rotor shaft

Gear hox

Generator

Fig.5.8 Vertical axis windmill

,
5.19
 A vertical axis windmill is a type of windmill in which the
axis of rotation of the rotor is perpendicular to the wind
direction. The main components of a vertical axis windmill are:
Rotor: It consists of the blades and the vertical shaft
Gearbox: It connects the shaft and the generator.
Generator: It converts the mechanical energy of the rotor
into electrical energy.

The gearbox and generator are positioned at the base of the

windmill, which makes maintenance easy.

M
The working principle of this windmill is based on drag.

A
Drag is the force that opposes the motion of an object when air
G
flows over its surface. The blades create different amounts of drag
PA

when they oppose the wind flow. This drag difference causes the
blades to rotate around the vertical axis. The rotor shaft attached
IP

with the blades is rotated. The rotor shaft drives the generator to
TH

produce electricity.
Advantages of windmills
PA

1) Wind power is freely available

2) Eco friendly method of power production
L

3) Conservation of fossil fuels for other uses.

A

4) Cost effective method

K

5) Easy to install
6) Low maintenance cost

Disadvantages
1) Wind is not consistent and steady.
2) Initial investment is high
3) Dangerous to wildlife
4) Noisy operation
5) Regular maintenance is needed

,
5.20
 REVIEW QUESTIONS

1) Define heat.
2) Explain various modes of heat transfer. Give examples.
3) What is internal combustion engine? Give its classification.
4) Explain the four stroke petrol engine with a neat sketch.
5) Explain the four stroke diesel engine with a neat sketch.
6) Compare petrol engine with diesel engine.
7) Write short notes on battery electric vehicle? Give examples.
8) List out the advantages and disadvantages of BEV.

M
9) Explain the working of a steam power plant with a line sketch.
10)
A
List out the advantages and disadvantages of steam power
G
plant.
PA

11) Explain the working of a nuclear power plant with a line

sketch.
IP

12) What are the advantages and disadvantages of nuclear

TH

power plant?
13) with a line sketch, explain the working of a solar power
PA

plant. State its advantages and disadvantages.

14) What is windmill. Explain the working of horizontal axis
L

windmill with a sketch.

A
K

15) Explain the working of vertical axis windmill with a sketch.

16) List out the advantages and disadvantages of windmills.

,
5.21
 Unit – I
ROLES AND RESPONSIBILITIES OF
MECHANICAL ENGINEER
1. What is mechanical engineering?
Mechanical engineering is a branch of engineering that
involves design, analysis, manufacturing and maintenance
of mechanical systems.

M
2. Who is a mechanical engineer?
A
A mechanical engineer is a professional who transforms an
G
idea into a product or a mechanical system through
PA

research, design, development, manufacturing, installation

and maintenance of mechanical components and systems
IP

related with the product.

TH

3. Describe the job of a mechanical engineer.

PA

The job of a mechanical engineer includes product design,

analysis and testing, material selection, prototyping,
quality assurance, research and development
L
A

4. List out the roles and responsibilities of a mechanical

K

engineer.
1) Designing and prototyping
2) Analysis and testing
3) Problem-solving
4) Collaboration
5) Production
6) Project management
7) Installation
8) Maintenance and repairs
9) Research and development

,
2 Marks Questions & Answers Q&A.1
 5. List out the various sectors in which job opportunities
available for mechanical engineer.
1) Manufacturing
2) Automobile
3) Power generation
4) Maintenance and Service
5) Design
6) Quality control
7) Materials management
8) Logistics
6. Give the importance of manufacturing sector.

M
Manufacturing is the process of converting raw

A
materials into more valuable goods.
G
Manufacturing engineering involves designing and
PA

developing manufacturing processes to improve

efficiency, productivity, and quality.
IP

The manufacturing industry plays a crucial role in the

TH

economic development of the country.

7. Name some manufacturing industries in India.
PA

Tata group of companies

Reliance industries
L

Mahindra group of companies

A

Larsen & Toubro (L&T)

K

Hindustan Unilever Limited (HUL)

Godrej group of companies
8. List out the various job titles for mechanical engineer
in manufacturing industries.
Production Engineer
Quality Control Engineer
Process Engineer
Plant Manager
Maintenance Engineer
Operations Manager, etc.
,
2 Marks Questions & Answers Q&A.2
 9. What is the importance of automobile industries?
The automotive industry comprises a wide range of
companies and organizations involved in the design,
development, manufacturing, marketing, selling, repairing,
and modification of motor vehicles. It is one of the world's
largest industries by revenue.
10. List out some automobile industries in India.
Maruti Suzuki India
Hyundai Motor India
Tata Motors

M
Mahindra & Mahindra (M&M)

A
Toyota Kirloskar India G
Honda Cars India
PA

11. List out the various job titles for mechanical engineer
in automobile industries.
IP

Design Engineer
TH

Manufacturing Engineer
Automotive Technician
PA

Quality Engineer
Research and Development Engineer
L

Production Engineer, etc.

A

12. Give the importance power generation

K

Power generation is important to fulfil the growing need of

the population. This field focuses on designing and
developing renewable energy sources like wind turbines,
solar panels, and hydroelectric power systems.
13. Name the major power generating companies in India.
Power Grid Corporation of India Ltd.
NTPC (National Thermal Power Corporation)
NHPC (National Hydroelectric Power Corporation)
Adani Power Limited

,
2 Marks Questions & Answers Q&A.3
 Tata Power Company Limited
JSW Energy Limited
14. What are the various job opportunities for mechanical
engineer in power generation sector?
Energy Engineer
Thermal Engineer
Renewable Energy Engineer
Power Plant Engineer
Operations Manager
Research and Development Engineer, etc.
15. What is the aim of maintenance and service?

M
A
The main aim of maintenance is to maintain the
G
functionality of the equipment and to minimize its
PA

breakdowns.
16. List out the various job opportunities for mechanical
IP

engineer in maintenance and service.

TH

Service Engineer
Quality Engineer
PA

Maintenance Engineer
Reliability Engineer
L

Maintenance Technician
A

Facility Maintenance Manager

K

Operations Manager
Maintenance Supervisor
Property Manager, etc.
17. What is industrial design? Mention the role of design
engineer.
Industrial design is the professional practice of
designing products, devices, objects, and services used
by millions of people around the world every day.

,
2 Marks Questions & Answers Q&A.4
 Design engineers work on creating and developing new
products and systems using computer-aided design
(CAD) software.
18. Name some product design companies in India.
Brand Provoke
Analogy Design
Workshore
Robosoft Technologies
Criador Labs
Code Theorem

M
19. What are roles of mechanical engineer in product

A
design field. G
Design Engineer
PA

CAD Designer
Drafting Technician
IP

Product Designer
TH

Design Analyst
Mechanical Designer
PA

Project Engineer
3D Designer, etc.
20. What is quality control? Give its importance.
L
A

Quality control refers to the set of activities that are

K

designed to ensure that a product or service meets the

specified quality standards.
Quality control is important for businesses because it
helps to improve customer satisfaction, increase
efficiency, increase reputation, reduce costs, improve
competitiveness, and a variety of other benefits.
21. List out the roles of mechanical engineer in quality
control.
Quality Engineer

,
2 Marks Questions & Answers Q&A.5
 Quality Inspector
Test Engineer
Quality Auditor
Quality Coordinator
Supplier Quality Engineer
Quality Assurance Engineer
Quality Control Engineer
22. What is materials management?
Materials management is related to planning, purchasing,
storing and providing the appropriate material of right
quality, right quantity at right place in right time. It ensures

M
smooth and unrestricted production, improves productivity,
and reduces the cost
A
G
PA

23. List out the various job opportunities for mechanical

engineer in material management.
IP

Materials Manager
TH

Supply Chain Manager

Inventory Manager
PA

Operations Manager
Purchasing Manager
Production Manager
L
A

Logistics Manager
K

Procurement Manager
Warehouse Manager, etc.
24. What is logistics?
Logistics is the process of planning and executing the
efficient transportation and storage of goods from the point
of origin to the point of consumption. The goal of logistics
is to meet customer requirements in a timely, cost-effective
manner.

,
2 Marks Questions & Answers Q&A.6
 25. List out the roles of mechanical engineer in the field of
logistics.
Logistics Engineer
Logistics Manager
Inventory Control Manager
Supply Chain Manager
Procurement Manager
Operations Manager
Transportation Manager
Facilities Manager
Service Manager

M
A
Unit – II
G
PA

ENGINEERING MATERIALS,
METAL FORMING AND JOINING
IP

1. Give the importance of materials.

TH

Materials are the building blocks of modern society.

PA

Use of materials is an essential requirement for the

development of engineering and technology.
Materials are the main component of all products,
L

structures, and machines.

A

They provide the basis for manufacturing, fabrication,

K

operations, constructions, etc.

2. What are the types of materials.
1) Metals 2) Ceramics 3) Polymers
4) Composites 5) Semi-conductors
3. Classify metals. Give examples.
Ferrous metals: Cast iron, mild steel, stainless steel, high
speed steel (HSS), etc.
Non-ferrous metals: Aluminium, copper, lead, zinc, tin, etc.

,
2 Marks Questions & Answers Q&A.7
 Alloys: Brass, bronze, nichrome, solder, duralumin, gun
metal, etc.
4. Differentiate: ferrous and non-ferrous metals.
Ferrous metals: These are metals which contain iron.
All ferrous metals are magnetic and give little resistance
to corrosion.
Non-ferrous metals: These are metals which do not
contain any iron. They are not magnetic and are usually
more resistant to corrosion than ferrous metals.
5. State the uses and applications of metals.

M
Automotive parts, industrial machinery, machine tools,

A
kitchen wares, steel structures, forgings, castings, surgical
G
and dental instruments, food processing machinery, etc.
PA

6. What are ceramics? Give examples.

Ceramics are solid compounds consisting of metallic or
IP

non-metallic elements. They are mainly oxides, nitrides,

TH

and carbides.
Example: Glasses, cements, clay products, refractories,
PA

and abrasives.
7. Write the uses of ceramics.
L
A

Tiles, bricks, terracotta, pottery, drain pipes, covers for

K

electrical cables, optical instruments, spark plugs, fiber

optics, artificial joints, space shuttle tiles, cooktops, race
car brakes, etc.
8. What are polymers. Give examples.
Polymers are large molecules made up of repeating
small simple chemical units.
Example: Plastics, rubbers, fibers, adhesives, and
coatings.

,
2 Marks Questions & Answers Q&A.8
 9. What are the types of polymers?
1) Thermoplastic polymers 2) Thermosetting polymers
3) Elastomers.
10. List out the applications of polymers.
Packaging, stationeries, plastic products, aircraft,
construction, rope, toys, plumbing pipes, electrical switches,
kitchen products, insulators, computer discs, paints, etc.
11. What is a composite? Give its classification.
A composite is a material in which one or more mutually
insoluble materials are mixed or bonded together.

M
Classification:

A
1) Particulate composites 2) Fibrous composites
G
3) Laminated composites.
PA

12. Give examples of composites.

Plywood, Carbon fiber-reinforced polymers (CFRP), Glass
IP

fiber-reinforced polymers (GFRP), Metal matrix composites

TH

(MMC), Ceramic matrix composites (CMC), etc.

13. What are the uses and applications of composites?
PA

Aerospace, architecture, construction, automotive, marine,

military, pipings, storage tanks, sports, transportation, etc.
L
A

14. What are semi-conductors? Give examples.

K

Semiconductors have electrical properties intermediate

between those of conductors and insulators.
Example: Silicon, Germanium, Selenium, Gallium,
Arsenic, etc.
15. List out any five mechanical properties.
1) Elasticity 2) Plasticity 3) Strength
4) Brittleness 5) Hardness

,
2 Marks Questions & Answers Q&A.9
 16. Define elasticity. Give its importance.
The property of material by which a body regains its
original shape and size after deformation when applied
forces are removed is known as elasticity.
The elasticity property is desirable in materials used for
manufacturing of tools and machine elements.
17. Name some materials having good elasticity.
1) Steel 2) Rubber
18. Define plasticity. Give its importance.
Plasticity is the property of a material by which a body

M
retains the deformation due to applied load without

A
rupture, even after the removal of applied load.
G
Plasticity plays an important role in manufacturing
PA

processes like forming, forging, swaging, coining,

extrusion, etc.
IP

19. Name some materials having good plasticity.

TH

1) Clay 2) Lead
PA

20. What is ductility? Mention its importance.

Ductility is the property of a material by which the
L

material can be drawn out or elongated into thin wires

A

without rupture by applying a tensile force.

K

This property is very important in manufacturing

processes like rolling, wire drawing, etc.
21. Name some materials having high weldability.
1) Mild steel 2) Copper 3)Aluminium
4) Zinc 5) Gold 6) Platinum
22. Define malleability. Give its importance.
Malleability is the property of a material by which the
material can be flattened into thin sheets without
cracking by hot or cold working processes.
,
2 Marks Questions & Answers Q&A.10
 This property is very important in manufacturing
processes like forging, hot rolling, drop forging, wire
drawing, etc.
23. Name some materials having high malleability.
1) Mild steel 2) Wrought iron
3) Copper 4) Aluminium
24. Define machinability. How it is expressed?
Machinability is the property of a material by which the
material can be easily machined by cutting tools in
various machining operations.

M
The machinability of different materials can be

A
compared with the help of machinability index.
G
25. What is castability?
PA

Castability is the property of a material by which the

material can be easily cast into different size and shapes.
IP

26. Define weldability. Give examples of materials having

TH

good weldability.
Weldability is the property of a material by which the
PA

material can be welded into a specific and suitable

designed structure and to perform satisfactorily in the
L

desired objective.
A

Example: Steel, aluminium, copper and brass have good

K

weldability.
27. Define strength. Give its importance.
Strength is a property of a material by which the material
can withstand or resist the action of external force or
load without breaking or yielding.
This property plays an important role in the designing of
various structures and machine elements.
28. Give examples of materials having more strength.
1) Tungsten 2) Steel 3) Titanium 4) Chromium
,
2 Marks Questions & Answers Q&A.11
 29. Define stiffness. Give its importance.
Stiffness is the property of a material to resist elastic
deformation or deflection due to the applied load. It is
also known as rigidity.
This property is very important in the design of beams,
shafts and springs.
30. Give examples of materials having high stiffness.
1) Steel 2)Aluminium 3) Brass
31. Define toughness. Where it is desirable?
Toughness is the property of a material to resist the

M
fracture by absorbing energy due to heavy shock loads
or blow, without rupture.
A
G
This property is desirable in structural members and
PA

machine elements which are subjected to absorb shock

and vibrations.
IP

32. Name some materials having high toughness.

TH

1) Cast iron 2) Mild steel 3) Brass

PA

33. Define brittleness. Where it is desirable?

Brittleness is the property of a material by which the
L

material will fail or fracture all of sudden without any

A

significant deformation. This property is opposite to

K

ductility.
This property is desirable in machine parts which may
be subjected to sudden compressive loads.
34. Name some materials having high brittleness.
1) Cast iron 2) Concrete 3) Glass 4) Stone
35. Define hardness. Give its importance.
Hardness is the ability of a material to resist surface
penetration, abrasion and scratching.

,
2 Marks Questions & Answers Q&A.12
 It is an important property involved in the design of
machine members such as gears, cams, chain sprockets,
etc. which are under constant rubbing action.
36. Give examples of materials having high hardness.
1) Hard steel 2) Cast iron 3) Glass 4) Diamond
37. Define wear resistance. How it is improved?
Wear resistance is the property of a material to resist wear.
Wear resistance can be increased by increasing the hardness
of the working surface by case hardening process.
38. Name some materials having high wear resistance.

M
1) Steel 2) Aluminum 3) Stainless steel 4) Titanium
A
G
39. Define fatigue. Where it is important?
PA

Fatigue of a material may be described as the failure of

the material when subjected to a number of cyclically
IP

changing loads in which the maximum stress developed

TH

in each cycle is well within the elastic range.

This property is important in machine elements such as
PA

motor shafts, bolts, springs, gear teeth, valves and

turbine blades.
L

40. Define fatigue strength.

A

The stress at which a material fails by fatigue is known as

K

fatigue strength.
41. Define endurance limit. Give its importance.
Endurance limit or fatigue limit is a maximum stress
below which a load may be repeatedly applied at infinite
number of times without causing failure of material by
fatigue.
This limiting stress is most important while designing
machine elements which are subjected to repeated or
cyclic loading.
,
2 Marks Questions & Answers Q&A.13
 42. Define creep. Where it is important?
Creep is the property of a material by which the material
is deformed slowly and progressively under a constant
load over a long period.
Example: Creep is considered important in I.C engine
components, components of gas turbines, steam turbines
and boilers working at high temperature, components of
rockets, missiles, etc.
43. List out any five thermal properties.
1) Specific heat capacity

M
2) Thermal conductivity

A
3) Thermal expansion G
4) Melting point
PA

5) Boiling point
44. Define specific heat capacity.
IP

Specific heat capacity is defined as the quantity of heat

TH

required to raise or lower the temperature of the unit mass

of the material through one degree.
PA

45. Define thermal conductivity.

It is defined as the amount of heat conducted in a unit time
L

through a unit area normal to the direction of heat flow.

A

46. What is thermal expansion. Define coefficient of linear

K

expansion.
Thermal expansion is the tendency of a material to
expand or contract in response to changes in
temperature.
The increase in length per unit length per degree rise in
temperature is called coefficient of linear expansion.
47. Define melting and boiling point.
The melting point is the temperature at which a solid
material melts and becomes a liquid.

,
2 Marks Questions & Answers Q&A.14
 The boiling point is the temperature at which a liquid
material boils and becomes a gas.
48. Define thermal shock resistance.
Thermal shock resistance can be defined as the ability of
material to withstand thermal stresses due to sudden
changes in the temperature at the surface of a solid body.
49. List out any four electrical properties of materials.
1) Capacitance
2) Electrical conductivity
3) Electrical resistivity

M
4) Dielectric strength
50. What is capacitance?
A
G
Capacitance is the capability of a material to store electric
PA

charge.
51. Define electrical conductivity. Give examples of good
IP

conductors.
TH

Electrical conductivity is the ability of a material to

conduct electrical current.
PA

Metals like copper and gold have high conductivity.

L

52. Define electrical resistivity. Give examples of good

A

insulators.
K

Electrical resistivity is defined as ability of the material

to resist the flow of electrical current.
Glass, plastic and silicone are good insulators.
53. What is dielectric strength?
It is the maximum electric field that the material can
withstand under ideal conditions without undergoing
electrical breakdown.
54. List out any five magnetic properties of materials.
1) Magnetic intensity

,
2 Marks Questions & Answers Q&A.15
 2) Magnetic flux density
3) Retentivity
4) Coercivity
5) Magnetic susceptibility
6) Magnetic permeability
55. Define magnetic intensity.
The external magnetic field that is only produced by
electric current flowing in a material is known as magnetic
intensity or magnetic field strength.
56. Define magnetic flux density.

M
The density of magnetic field lines that pass through the

A
material per square meter is known as magnetic flux density.
G
57. Define retentivity.
PA

Retentivity is the ability of a material to retain magnetization.

58. Define coercivity.
IP

Coercivity is the ability of a material to withstand the

TH

external magnetic field without being demagnetized.

59. Define magnetic susceptibility.
PA

Magnetic susceptibility is the measure of the magnetisation

of a material in response to the applied magnetic field.
L
A

60. Define magnetic permeability.

K

Magnetic permeability is the measure of the resistance of a

material against the formation of a magnetic field.
61. List out any five chemical properties of materials.
1) Reactivity 2) Flammability 3) Toxicity
4) Acidity or Alkalinity 5) Corrosion resistance
62. Define metal forming.
Metal forming can be defined as a process in which the
desired size and shape are obtained through the
deformation of metals plastically under the action of
externally applied forces.
,
2 Marks Questions & Answers Q&A.16
 63. What are the types of metal forming?
1) Hot working 2) Cold working
64. Define hot working. Give examples.
Hot working is the process of heating the metal above
its recrystallization temperature to undergo plastic
deformation and to get the required shape.
Examples of hot working operations :
1) Rolling 2) Forging 3) Swaging
4) Extrusion 5) Drawing 6) Hot spinning
65. List out the advantages of hot working.

M
1) The toughness and ductility of metal can be improved.

A
2) The hardness due to the plastic deformation can be
G
removed.
PA

3) No internal stresses are produced in the metal.

4) Less amount of force is sufficient to deform the metal.
IP

5) It is a quick and economical process.

TH

6) All methods can be formed to required shape by this

method.
PA

66. Define cold working. Give examples.

Cold working of a metal is carried out below its
L

recrystallisation temperature. Cold working involves

A

plastic deformation of a metal, which results in strain

K

hardening.
Examples of cold working operations
1) Cold rolling 2) Extrusion 3) Wire drawing
4) Forging 5) Shearing 6) Bending
7) Pressing 8) Squeezing
67. List out the advantages of cold working.
1) Mechanical properties are improved
2) Smooth surface finish can be easily produced.
3) Better dimensional accuracy is achieved.

,
2 Marks Questions & Answers Q&A.17
 4) Strength and hardness of the metal are increased
5) No formation of oxide
6) It is easier to handle cold parts.
68. What is the use of drop hammer? Give its types.
Drop hammers are used in drop forging operations.
Types: 1) Gravity hammer 2) Power drop hammer
3) Air lift hammer
69. What is hot rolling?
Rolling is a process of forming metal to the required shape
by passing it between rotating rolls. When the metal to be

M
rolled is heated above its recrystallization temperature, it is

A
called hot rolling. G
70. State the applications of rolling.
PA

Rolling is used to produce components having constant

cross-section throughout its length. This includes sheets,
IP

plates, rounds, squares, wires, hexagonal bars, I-sections,

TH

T-sections, channels, angles and many other shapes.

71. What is roll forging? Give its applications.
PA

Roll forging is a process of producing components with

varying cross sections by pressing the heated work piece
L

between two rotating rolls.

A

Applications: Automobile axles, levers, leaf springs,

K

tapered tube are produced by roll forging.

72. What are the types of hot extrusion?
1) Direct or forward hot extrusion
2) Indirect or backward hot extrusion
3) Tube extrusion
73. Give the difference between direct extrusion and
indirect extrusion.
In direct extrusion, metal is forced to flow in the
direction of ram movement.
,
2 Marks Questions & Answers Q&A.18
 In Indirect extrusion, metal is forced to flow in the
opposite direction of ram movement.
74. Write the applications of hot extrusion.
The hot extrusion process is widely used to manufacture
products from aluminium, copper and their alloys. This
includes rods, bars, wires, tubes, structural shapes, aircraft
parts, etc.
75. What is the use of mechanical press?
Mechanical press is a machine used for pressing or cutting
the metal to get required shape by applying mechanical

M
force or pressure. It is used for producing finished products

A
from sheet metal at fast rate. G
76. List out some sheet metal press working operations.
PA

Pressing, bending, curling, piercing, deep drawing,

straightening, trimming, assembling of various steel
IP

components, etc.
TH

77. What is wire drawing?

Wire drawing is a metal forming process used to reduce the
PA

cross-section of a wire by pulling it through a single die or

series of dies.
L

78. Name the applications of wire drawing.

A
K

Wire drawing is used to produce electrical wires, cables,

tension-loaded structural components, springs, paper clips,
spokes for wheels, jewellery, stringed musical instruments, etc.
79. What is metal joining?
Metal joining is one of the manufacturing processes by
which two or more metal parts are assembled together to
obtain a single unit.
80. What are the two types of metal joining processes? Give
examples.

,
2 Marks Questions & Answers Q&A.19
 1) Temporary joining processes: Fasteners, press fits,
mechanical joints, etc.
2) Permanent joining processes: Welding, brazing,
soldering riveting, etc.
81. Give the difference between temporary and permanent
joining.
Temporary Joining Permanent Joining
1) Can be dismantled without Cannot be dismantled
breaking the assembled parts. without breaking parts.
2) Suitable where frequent Suitable where joint is to

M
assembly and disassembly are be fixed for longer period.

A
required. G
3) Strength of joint is low. Strength of joint is high.
PA

4) Joints are not leak-proof. Joints are not leak-proof.

6) Repair and maintenance is Repair and maintenance
IP

easy. is difficult.
TH

82. What is bolted joint? Give its applications.

PA

A bolted joint consists of a long bolt with external

threads and a bolt with mating internal threads.
Applications: Construction, assembly, fabrication,
L
A

machine design, pipe flanges, automotive engines, etc.

K

83. How press fit joint is achieved? Give its applications.

Press fit joint is achieved by inserting a shaft tightly into
a slightly smaller hole in another part.
Applications: Bearing-shaft assembly, automobile,
plumbing, electronics, robotics, etc.
84. Give some examples of mechanical joints.
1) Pin joint 2) Ball joint 3) Knuckle joint
4) Cotter joint 5) Universal joint

,
2 Marks Questions & Answers Q&A.20
 85. Define welding.
Welding is the process of joining similar or different metal
by heating.
86. What are the types of welding? Give examples.
1) Plastic welding or pressure welding: Spot welding,
butt welding, seam welding, projection welding, etc.
2) Fusion welding or non- pressure welding: Gas
welding, electric arc welding, etc.
87. Give the difference between plastic welding and fusion
welding.

M
In plastic welding, the metal pieces are heated to plastic

A
stage and joined by applying sufficient pressure.
G
In fusion welding, the metal pieces are melted and joined
PA

with the help of filler material without applying

pressure.
IP

88. List out the applications of welding.

TH

Fabrication of automobile bodies, air craft, machine

frames, boilers, ship building, railway wagons, etc.
PA

89. What is soldering?

Soldering is the process of joining two similar or dissimilar
L
A

metals by using a low melting alloy called solder.

K

90. What is solder?

Solder is an alloy of tin and lead.
91. List out the applications of soldering.
Connections in wireless set, T.V. sets, etc.
Wiring joints in electrical connections, battery and other
terminals.
Radiator brass tubes for motor car.
Copper tubing carrying liquid fuel, gas or air used in
engines.
Drain water pipes.
,
2 Marks Questions & Answers Q&A.21
 92. What is brazing?
Brazing is the process of joining two similar or dissimilar
metals by using a high melting alloy called spelter.
93. What is spelter?
Spelter is a mixture of copper and zinc alloy.
94. Name the applications of brazing.
Radiator works, joining pipes with drums and tanks,
joining carbide tips on tool shank, etc.
95. What is riveting?
Riveting is a method of joining two or more components

M
together using rivets.
96. What are the applications of riveting? A
G
PA

Structural works, ship building, bridges, roof trusses, tanks,

boiler shells, etc.
IP

Unit – III
TH

FUNDAMENTALS OF MACHINE TOOLS

PA

1. What is machining?
Machining is the process of removal of material from the
L

workpiece to obtain a finished product of the desired size,

A

shape and surface quality.

K

2. What is a machine tool?

A machine tool is a power-driven machine used for
removing material by machining operations.
3. List out the common machine tools.
1) Lathes 2) Planers
3) Shapers 4) Slotters
5) Milling machines 6) Drilling machines
7) Boring machines 8) Grinding machines
9) Broaching machines
,
2 Marks Questions & Answers Q&A.22
 4. What is lathe? (or) What is the principle of lathe?
Lathe is a machine tool used for removing metal from
cylindrical work piece to get required shape and size. The
work piece is held in the lathe and rotated about its axis.
The single point cutting tool is moved parallel to the axis
of work piece to produce cylindrical surface.
5. Lis the important parts in a lathe.
1) Bed 2) Head stock 3) Carriage 4) Tail stock
6. What are the two types of head stock in a lathe?
1) Back geared head stock 2) All geared head stock

M
7. What are the parts mounted on the carriage of a lathe?
1) Saddle A
G
2) Cross slide
PA

3) Compound rest or compound slide

4) Tool post
IP

5) Apron
TH

8. List out the various operations done on a lathe.

PA

1) Straight turning 2) Step turning 3) Facing

4) Chamfering 5) Grooving 6) Parting off
7) Knurling 8) Drilling 9) Reaming
L

10) Boring 11) Taper turning 12) Thread cutting

A
K

9. What is drilling machine?

Drilling is the process of producing circular holes in a work
piece. The machine used for this operation is called drilling
machine and the tool is called drill or drill bit.
10. Write the principle of drilling.
The workpiece is held securely in place on the drill table
using vises and clamps. The hole is produced by giving
axial movement to the rotating drill against the work piece.

,
2 Marks Questions & Answers Q&A.23
 11. List out the types of drilling machines.
1) Portable drilling machine
2) Bench type - sensitive drilling machine
3) Floor type - upright drilling machine
4) Radial drilling machine
(i) Plain type (ii) Semi universal type (iii) Universal type
5) Gang drilling machine
6) Multi spindle drilling machine
7) Deep hole drilling machine: (i) Vertical type
(ii) Horizontal type
12. Name the important parts in a drilling machine.

M
1) Base 2) Column 3) Table 4) Spindle head
A
G
13. What is milling machine?
PA

Milling is the process of removing metal from the work

piece by using a multi point cutter. The machine used for
IP

this process is known as milling machine.

TH

14. Write the principle of milling.

When the work piece is fed against the cutter, the metal is
PA

removed in the form of chips. As multi point cutter is used,

metal is removed quickly.
L
A

15. What are the two methods of milling?

K

1) Up milling or conventional milling

2) Down milling or climb milling
16. Give the difference between up milling and down milling.
In up milling, metal is removed when the cutter teeth
move upwards. The cutter rotates opposite to the
direction of feed of work piece.
In down milling, metal is removed when the cutter teeth
move downwards. The cutter rotates in the same
direction as the feed of work piece.

,
2 Marks Questions & Answers Q&A.24
 17. Lis the important parts in a milling machine.
1) Base 2) Column 3) Knee 4) Saddle
5)Table 6) Spindle 7) Over arm
18. Define CNC.
Computer numerical control (CNC) is defined as a
numerical control (NC) system that utilizes a dedicated
microcomputer to perform some or all of the basic
numerical control functions.
19. What numerical control(NC)?
Numerical control (NC) system is a method of automation

M
in which various functions of machine tools are controlled
by letters, numbers and symbols.
A
G
20. What are the basic components in a CNC system?
PA

1) Program of instructions
2) Machine Control Unit (MCU)
IP

3) Machine tool
TH

21. What is part program in CNC?

PA

The part program consists of instructions written in the

numerical codes that constitutes the basic operations to be
carried out in machining of the part.
L
A

22. What is the function of MCU in CNC?

K

Machine control unit consists of the electronics and

hardwares that read and interpret the part program and
convert it into mechanical actions of the machine tool.
23. List out the elements in MCU.
Central processing unit
Memory
Input / Output interface
Controls for machine tool axes and spindle speed.
Programmable logic controller

,
2 Marks Questions & Answers Q&A.25
 24. What is machine tool in a CNC system?
Machine tool is the part of the CNC system that performs
useful work. It accomplishes the processing steps to
transform the starting work piece into a completed part.
25. List out the important features in a CNC system.
Storage of part programs into computer memory.
Automatic determination of tool path.
Simultaneous execution of various functions.
Automatic tool changing.
Automatic work piece positioning.
Automatic checking of finished work piece dimensions.

M
Tool breakage detection and recovery.

A
26. List out the applications of CNC in machine tools.
G
CNC lathe
PA

CNC boring mill

CNC drill press
IP

CNC milling machine

TH

CNC cylindrical grinder

27. Write the applications of CNC in metal working.
PA

Punch presses for sheet metal hole punching

Presses for sheet metal bending
Welding machines
L
A

Flame cutting machines

Laser cutting machines
K

Tube bending machines

28. What are the common applications of CNC?
Assembly machines
Electrical wire wrap machines
Component insertion machines
Inspection machines
Coordinate measuring machines
Cloth cutting machines
Automated knitting machines
Automated riveting machines
,
2 Marks Questions & Answers Q&A.26
 Unit – IV
POWER TRANSMISSION DRIVES
AND LUBRICATION
1. What are belt drives?
Belt drives are used for transmitting power from one shaft
to another shaft.
2. What is driver pulley and driven pulley in belt drives?
The pulley which is keyed to the rotating shaft is known
as driver pulley.

M
The pulley which is keyed to the shaft which is to be

A
rotated is known as driven pulley or follower pulley.
G
3. What are the types of belt drive?
PA

1) Flat belt drive

2) V–belt drive
IP

3) Circular belt or rope drive

TH

4. Where the flat belt drives are used?

PA

Flat belt drives are used where a medium amount of power

is to be transmitted from one pulley to another pulley. They
connect the pulleys, which are at a distance up to 10m.
L
A

5. What are the important types of flat belt drives?

K

(i) Open belt drive (ii) Cross belt drive

(iii) Compound belt drive
6. Where the open belt drive and cross belt drives are
used?
Open belt drive is used where the two pulleys are
arranged in parallel and both are to be rotated in same
direction
Cross belt drive is used where the shafts are arranged in
parallel and rotate in the opposite direction.

,
2 Marks Questions & Answers Q&A.27
 7. Write the applications of flat belt drive.
Agricultural machines
Machine tools
Flour mills
Generators
Fans
Blowers
Pump
Textile machineries
Sugar mills, etc.
8. What are the advantages of flat belt drive?

M
1) Simple construction.
2) Cost of the belt is less. A
G
3) Runs smoothly.
PA

4) Suitable for transmitting power between two shafts

IP

arranged in any position.

5) Transmits power over considerable distance between
TH

driver and driven.

PA

9. When the V-belts are used?

V-belts are used when large amount of power is to be
transmitted from one pulley to another. They are used to
L
A

connect pulleys which are very near to each other.

K

10. List out the applications of V-belts.

Agriculture machines
Generators
Machine tools
Fans
Blowers
Pumps
Compressors
Textile machineries, etc.

,
2 Marks Questions & Answers Q&A.28
 11. What are the advantages of V-belts?
1) Suitable for transmission of power for short centre
distance
2) Space required for the drive is less.
3) Less vibration and noise.
4) Transmits more power.
5) Slip of the belt will not occur.
6) Replacement and maintenance is easy.
12. When the rope drive is preferred?
The rope drive is preferred when the centre distance
between the pulleys are more than 5 metre.

M
Rope drive can be used when there is misalignment
A
between the pulleys, fluctuating temperature and
G
humidity.
PA

13. Mention the applications of rope drives.

IP

Hand operated hoisting machines.

TH

Cranes, conveyors, elevators, etc.

Hoisting purposes in mines and quarries.
PA

Textile industries.
Tram ways, rope cars, etc.
L

14. List out the advantages of rope drives.

A

1) Weight of the belt is less.

K

2) Cost of the belt is low.

3) More durable and reliable
4) Frictional grip is more.
5) Large amount of power can be transmitted.
6) Suitable for transmission of power for large
distances.
15. When the chain drive is used?
Chain drives are used when the power is transmitted over a
shorter distance

,
2 Marks Questions & Answers Q&A.29
 16. List out the applications of chain drives.
Bicycles
Motor vehicles
Agricultural machineries
Conveyors
Hoists
Rolling mills
Road rollers, etc.
17. State the advantages of chain drives.
1) Positive non–slip drive
2) Compact and occupies less space.

M
3) Transmits large amount of power.

A
4) Absorbs shocks. G
5) Useful for low speed and high torque transmission.
PA

6) More durable.
18. Where the gear drives are used?
IP

Gear drives are used to transmit power from one shaft to

TH

another shaft where constant velocity ratio is essential.

19. Classify the gear drives according to the position of axes
PA

of shafts.
i) Parallel shafts drive ii) Intersecting shafts drive
L

iii) Non–intersecting or skew shafts drive

A

20. Classify the gear drives according to the type of

K

gearing.
i) External gear drive ii) Internal gear drive
iii) Rack and pinion drive
21. What are types of gear drives?
1) Spur gear drive
2) Helical gear rive
3) Bevel gear drive
4) Worm and worm wheel drive
5) Rack and pinion drive

,
2 Marks Questions & Answers Q&A.30
 22. What is spur gear? Where it is used?
The gears in which teeth are cut on the periphery of a
cylindrical disc at equal space parallel to the axis of the
wheel are known as spur gears.
Spur gears are used to transmit motion between two
parallel shafts.
23. List out the applications of spur gear drive.
1) Transmission of motion from main spindle to lead
screw in lathe.
2) Head stock back gear mechanism of lathe.

M
3) Gear box of automobiles.

A
4) Watches and clocks.
5) Gear pumps, toys, cameras and electrical
G
PA

appliances.
24. What is helical gear? Where it is used?
IP

The gears in which helical teeth are cut at an angle to

TH

the axis of rotation are known as helical gears.

Helical gears are used to transmit motion between two
PA

parallel or non–parallel or intersecting shafts.

25. What are heringbone gears?
L

If double helix is provided in helical gears, such gears are

A

called herringbone gears.

K

26. State the applications of helical gear drives.

1) Gear box and final drive of automobiles
2) Cam shaft of I.C engines.
3) Timing gears in I.C engines.
4) Oil pumps.
27. What is bevel gear? Where it is used?
The gears in which the teeth are cut on the surface of a
truncated cone are known as bevel gears.

,
2 Marks Questions & Answers Q&A.31
 Bevel gears are used to transmit motion between two
shafts, which are inclined at an angle to each other.
28. What are mitre gears?
If two bevel gears are symmetrical to each other and
o
transmit motion at 90 , such gears are called as mitre gears.
29. List out the applications of bevel gear drives.
1) Hand drilling machine.
2) Differential of automobiles.
3) Drill chuck key.
4) Worktable of machine tools.

M
30. Where the worm and worm wheel drive is used?

A
Worm and worm wheel drives are used to transmit motion
G
between two shafts, which are perpendicular to each other.
PA

31. List out the applications of worm and worm wheel

drive.
IP

1) Indexing heads.
TH

2) Final drive and steering gear box of automobiles.

3) Wind shield wiper.
PA

32. What is rack and pinion?

Rack is a rectangular bar on which straight teeth are cut
L
A

parallel to the axis of pinion. Pinion is a small spur gear.

K

33. What is the main use of rack and pinion drive?

The rack and pinion drive is used to convert rotary motion
into linear motion and linear motion into rotary motion.
34. Name the applications of rack and pinion drive.
1) Moving the carriage in lathe
2) Movement of spindle in drilling machine
3) Movement of table in planning machine.
4) Steering gear box of automobiles.
5) Fuel injection pump of diesel engine.

,
2 Marks Questions & Answers Q&A.32
 35. List out the advantages of gear drives.
1) Transmits motion at exact velocity ratio.
2) High efficiency.
3) Transmits a large power.
4) Compact layout.
5) No slip as in belt drives.
6) Reliable service.
36. What is cam and follower?
A cam is a rotating machine element which gives
reciprocating or oscillating motion to another element
known as follower.

M
A
37. What are the types of cams? G
1) Plate cam 2) Cylindrical cam
PA

3) Wedge cam 4) Spherical cam

38. What are the types of follower?
IP

1) Knife edge follower 2) Roller follower

TH

3) Flat-faced follower 4) Spherical follower

5) Radial follower 6) Offset follower, etc.
PA

39. List out the applications of cam drive.

1) Internal combustion engines
L

2) Automatic lathes
A

3) Gear cutting machines

K

4) Paper cutting and printing machines

5) Automatic indexing machines
6) Wall clocks
40. Give the classification of lubricants.
1) Solid lubricants
2) Semi–solid lubricants
3) Liquid lubricants

,
2 Marks Questions & Answers Q&A.33
 41. Where solid lubricants are used? Give examples.
Solid lubricants are used to reduce friction where oil
film cannot be maintained because of high pressure or
temperature.
Example: Graphite, wax, mica, French chalk, etc.
42. Where semi-solid lubricants are used? Give examples.
Semi-solid lubricants are used where slow speed and
heavy pressure exist and where oil drip from the bearing
is undesirable.
Example: Grease

M
43. Where liquid lubricants are preferred? Give examples.
A
Liquid lubricants are preferred where they may be
G
retained.
PA

Example: Mineral oils and synthetic oils.

IP

44. What are the purposes of lubrication?

TH

1) To reduce friction between moving parts

2) To reduce wear and tear of the bearing surfaces
PA

3) To dissipate the heat generated from the moving parts

4) To reduce the noise while the moving parts rub against
L

each other
A

5) To protect the bearing surfaces from water, dirt, etc.

K

6) To provide cooling effect to the rubbing parts

45. List out important properties of lubricants.
1) Viscosity 2) Oiliness 3) Flash point
4) Fire point 5) Volatility 6) Corrosion resistance
7) Stability 8) Film strength
46. Define viscosity. State its importance in lubricants.
Viscosity is the measure of degree of fluidity of an oil
by which it can withstand high pressure or load without
squeezing out form the bearing surface.

,
2 Marks Questions & Answers Q&A.34
 Viscosity of the lubricating oil should not fall below a
certain specified value at highest operating temperature
of the bearing.
47. What is oiliness? Give its importance in lubricants.
Oiliness is the ability of an oil to spread and adhere itself
firmly with the bearing surfaces.
Oiliness of the lubricating oil should be high for better
lubrication.
48. What is flash point? State its importance in lubricants.
Flash point of oil is the lowest temperature at which it

M
gives off enough vapour so that a momentary flash is

A
obtained when a flame is brought near the oil surface.
G
The flash point of the lubricant oil should be higher than
PA

the operating temperature of the bearing.

49. Define fire point.
IP

Fire point of oil is the lowest temperature at which it

TH

catches fire and burns continuously. Fire point is always

greater than the flash point.
PA

50. Define volatility. Give its importance in lubricants.

Oil may evaporate, when it is exposed to a high
L

temperature for long time. This property is known as

A

volatility.
K

The lubricating oil should have low volatility at the

operating temperature of the bearing.
51. What is demulsibility? State its importance in
lubricants.
The property of resisting emulsification is known as
demulsibility.
The lubricating oil should not form an emulsion when
brought in contact with water.

,
2 Marks Questions & Answers Q&A.35
 52. What is foaming? State its effects on lubricants.
Foaming is the condition in which minute air bubbles
are held in the oil.
This will reduce mass flow of oil and hence the
lubricating oil should be free from foaming trouble.
53. What is stability? Give its importance in lubricants.
Stability is an ability of an oil to resist oxidation.
Lubricating oil should have high stability.
54. What is film strength of a lubricant?
Film strength is the property of the lubricating oil due to

M
which the oil retains a thin film between the bearing

A
surfaces even at high speed and load.
G
55. What are the common methods of lubrication?
PA

1) Ring oiler lubrication

2) Drip feed lubrication
IP

3) Grease cup lubrication.

TH

56. What is the principle of ring oiler lubrication?

Ring oiler lubrication is a type of splash lubrication. This
PA

method works on the principle of adhesion.

57. State the applications of ring oiler lubrication?
L
A

Ring oiler lubrication is used for lubricating head stock of

K

the lathe, stationary equipments like compressors,

generators, motors, etc.
58. What is the principle of drip feed lubrication?
Drip feed lubrication is a type of gravity feed lubrication
system.
59. Write the applications of drip feed lubrication.
Drip feed lubrication is used for lubricating external
moving parts such as bearings, cross head, crank pins of
internal combustion engines.

,
2 Marks Questions & Answers Q&A.36
 60. What is the principle of grease cup lubrication method?
Grease cup lubrication is a type of force feed lubrication
system.
61. State the uses of grease cup lubrication.
Grease cup lubrication is used in tractors, lawnmowers,
industrial plant equipment, trucks, etc.

Unit – V
FUNDAMENTALS OF
HEAT POWER ENGINEERING

M
A
1. Define heat. G
Heat is defined as the energy transferred across the
PA

boundary of a system due to the temperature difference

between the system and the surroundings.
IP

2. Write the equation for heat transfer.

TH

Heat transfer is given by, 𝑸 = 𝒎 𝑪 (𝑻𝟐 − 𝑻𝟏 )

where, 𝑄 = Heat transfer (J/kg)
PA

𝑚 = Mass of the substance (kg)

C = specific heat of the substance (J/kg.K)
L

𝑇2 = Final temperature (K)

A

𝑇1 = Initial temperature (K)

K

3. What are the modes of heat transfer?

1) Conduction 2) Convection 3) Radiation
4. Define conduction.
Conduction is the transfer of heat energy by microscopic
diffusion and collisions of particles within a body due to
a temperature gradient.
It is also defined as the transfer of energy through the
direct physical contact of matter or particles.

,
2 Marks Questions & Answers Q&A.37
 5. Give examples of conduction.
Heat flow from the hot to cold fluid in a heat exchanger
Heating and cooling of the water of an I.C engine.
Cooling of castings in a foundry.
Heat transfer from our hands to ice cube
Heat transfer from hot tea cup to our hands
Ironing of clothes
6. Define convection.
Convection is the transfer of thermal energy from one place
to another by the movement of liquid or gases.

M
7. What are the two types of convection?

A
1) Free convection 2) Forced convection.
G
8. Give examples of convection.
PA

The upward flow of air due to a fire or hot object

The circulation of water in a pot that is heated from
IP

bottom.
TH

Cooling of billets in the atmosphere.

Flow of water in condenser tubes
PA

Fluid passing through the tubes of a heat exchanger

Cooling of internal combustion engines
L

9. Define thermal radiation.

A

Thermal radiation is electromagnetic radiation generated

K

by the thermal motion of charged particles in matter.

10. Give examples of thermal radiation.
Visible light from sun
Infrared light emitted by an incandescent light bulb
Infrared radiation emitted by animals
11. What is internal combustion (IC) engine?
Internal combustion (I.C) engine is a heat engine in which
combustion of fuel takes place inside the engine cylinder.

,
2 Marks Questions & Answers Q&A.38
 12. Give examples of internal combustion (IC) engines.
1) Petrol engine 2) Diesel engine
3) Gas engine 4) Gas turbine
13. Classify I.C engines based on the type of fuel used.
(a) Petrol engines (b) Diesel engines (c) Gas engines
14. Classify I.C engines based on the number of strokes per
cycle.
(a) Four stroke engine (b) Two stroke engine
15. Classify I.C engines based on the method of ignition.
(a) Spark Ignition (S.I) engines

M
(b) Compression Ignition (C.I) engines
16. A
Classify I.C engines based on the arrangement of
G
cylinders.
PA

(a) Vertical engines (b) Horizontal engines

IP

(c) V-type engines (d) In-line engines

(e) Radial engines
TH

17. What are the major components in a four stroke petrol

PA

engine?
1) Cylinder 2) Piston 3) Connecting rod
4) Crank 5) Crank shaft 6) Inlet valve
L
A

7) Exhaust valve 8) Spark plug

K

18. Why petrol engines are called spark ignition (SI)

engines?
In petrol engines, as the air fuel mixture is ignited by a
spark plug, it is also known as spark ignition engines.
19. What are the four strokes in a four stroke petrol
engine?
(1) Suction stroke (2) Compression stroke
(3) Expansion stroke (4) Exhaust stroke

,
2 Marks Questions & Answers Q&A.39
 20. What happens during suction stroke in petrol engine?
During suction stroke, the required air–fuel mixture is
sucked into the engine cylinder.
21. What happens during compression stroke in petrol
engine?
During compression stroke, the air–fuel mixture inside the
cylinder is compressed.
22. How ignition takes place in petrol engine?
When the piston reaches near top dead centre (TDC), an
electric spark is produced by the spark plug. The

M
compressed air–fuel mixture is ignited by the spark.
23.
A
What happens during expansion stroke in petrol
G
engine?
PA

During expansion stroke, the heat energy is converted into

useful mechanical work.
IP

24. What happens during exhaust stroke in petrol engine?

TH

During exhaust stroke, the burnt gases are exhausted from

the cylinder.
PA

25. Why diesel engines are called compression ignition (CI)

engines?
L
A

In diesel engines, as the air–fuel mixture is ignited due to

K

the temperature developed by the compression, it is also

known as compression ignition engines.
26. What are the major components in a four stroke diesel
engine?
1) Cylinder 2) Piston 3) Connecting rod
4) Crank 5) Crank shaft 6) Inlet valve
7) Exhaust valve 8) Fuel injector
27. What happens during suction stroke in diesel engine?
During suction stroke, the air is sucked into the engine
cylinder.
,
2 Marks Questions & Answers Q&A.40
 28. What happens during compression stroke in diesel
engine?
During compression stroke, the air inside the cylinder is
compressed.
29. How ignition takes place in diesel engine?
When the piston reaches near top dead centre (TDC), the
fuel is injected into the cylinder in the form of fine spray
with the help of fuel injector. Due to high pressure and
temperature of compressed air, the air–fuel mixture is
ignited.

M
30. Give the comparison of petrol engine with diesel engine.
Petrol engines
A
Diesel engines
G
1) Air–fuel mixture is Air alone is sucked into the
PA

sucked into the cylinder cylinder during suction

during suction stroke. stroke.
IP

3) Carburetor and spark Fuel injection pump and

TH

plugs are provided. injectors are provided.

4) Ignition of air–fuel Ignition of air–fuel mixture
PA

mixture takes place by an takes place due to the heat

electric spark produced developed by the
L

by the spark plug. compression of air.

A

State the uses of petrol engines.

K

31.
Petrol engines are widely used in light vehicles,
automobiles, airplanes, etc.
32. State the uses of diesel engines.
Diesel engines are widely used in heavy vehicles such as
buses, lorries, trucks, tractors, etc.
33. What is battery electric vehicle (BEV)?
Battery Electric Vehicle (BEV) is a fully electric vehicle
with rechargeable batteries. The electricity required to
drive the vehicle is stored in a large battery pack.
,
2 Marks Questions & Answers Q&A.41
 34. What are the main components of BEV?
1) Battery 2) Inverter 3) Motor
4) Controller 5) Reduction gear
35. What is the function of inverter in BEV?
Inverter converts DC power from the battery to AC power.
36. Give examples of BEV.
Hyundai Kona
Tata Tiago EV
Tata Tigor EV
Mahindra XUV300 EV

M
Mahindra E Verito
MG ZS EV A
G
PA

Mercedes-Benz EQB
BYD Atto 3
IP

Kia EV6
TH

BMW iX
37. List out the advantages of battery electric vehicles (BEV).
PA

1) Lower running cost

2) Low maintenance cost
L

3) Better performance
A

4) Zero tailpipe emissions

K

5) Quiet in operation
6) Convenience of charging at home
38. What is steam power plant?
Steam power plant is a type of power station in which heat
energy is converted into electrical energy.
39. State the principle of steam power plant?
The heat is produced by burning coal. The heat is used to
boil water in a large boiler to produce high pressure steam.

,
2 Marks Questions & Answers Q&A.42
 The steam drives a steam turbine connected to an electrical
generator.
40. List out the important components in steam power
plant.
1) Feed pump 2) Boiler 3) Turbine
4) Condenser 5) Air preheater 6) Super heater
7) Economiser 8) Chimney
41. State the advantages of steam power plant.
1) The plant life is more as compared to other plants.
2) Initial cost is less than other plants.

M
3) Repair and maintenance cost is comparatively low.

A
4) Suitable for varying load conditions.
G
5) No transmission losses.
PA

6) Skilled operators are not required.

42. State the principle of nuclear power plant?
IP

A large amount of heat is produced by the nuclear fission

TH

of the fuel. The heat is used to produce high pressure steam

in a steam generator. The steam drives a steam turbine
PA

connected to an electrical generator.

43. List out the important components in nuclear power
L

plant.
A

1) Nuclear reactor 2) Steam generator 3) Steam turbine

K

4) Coolant pump 5) Feed pump 6) Steam condenser

7) Electric generator
44. List out the advantages of nuclear power plant.
1) Space requirement is less.
2) Very less fuel consumption.
3) Fuel transportation cost is low.
4) Plant operation is not affected by bad weather condition.
5) Conservation of fossil fuels for other needs.
6) Produces more power.

,
2 Marks Questions & Answers Q&A.43
 45. State the principle of solar power plant.
A solar power plant is based on the conversion of sunlight
into electricity using photovoltaics (PV).
46. What is solar cell?
A solar cell is a device that converts light into electric
current using the photovoltaic effect.
47. Define photovoltaic effect.
The photovoltaic effect is the generation of electric current
in a material when exposed to light.
48. What are the main components of solar power plant?

M
1) Solar panels 2) Batteries 3) Inverter
49. A
List out the advantages of solar power plant.
G
PA

1) Reduction in electricity cost

2) One time investment and free power for life
IP

3) Eco friendly method of power production

TH

4) Conservation of fossil fuels for other uses.

5) Cost effective method
PA

6) Low maintenance cost

50. State the principle of wind mills.
L

A windmill converts the kinetic energy of moving mass of

A

air into mechanical energy. This mechanical energy can be

K

used to drive a machine or to drive a generator.

51. What are the types of windmills?
1) Horizontal axis windmill 2) Vertical axis windmill
52. List out the main components of a windmill.
Rotor with blades and shaft
Gear box
Generator

,
2 Marks Questions & Answers Q&A.44
 53. Give the difference between horizontal axis and vertical
axis windmills.
In horizontal axis windmill, the axis of rotation of the
rotor is horizontal to the ground.
In vertical axis windmill, the axis of rotation of the rotor
is perpendicular to the wind direction.
54. List out the advantages of windmills.
1) Wind power is freely available
2) Eco friendly method of power production
3) Conservation of fossil fuels for other uses.

M
4) Cost effective method

A
5) Easy to install
6) Low maintenance cost
G
PA
IP
TH
PA
L
A
K

,
2 Marks Questions & Answers Q&A.45
 BASICS OF MECHANICAL ENGINEERING
MODEL QUESTION PAPER - I
Time: 3 Hrs. Max. Marks : 100
[N.B: (1) Answer any 15 questions under Part – A.
All questions carry equal marks. (15 × 2 = 30)
(2) Answer all questions, choosing any two sub-
divisions from each question under Part – B. All
questions carry equal marks (5 × 14 = 70) (7+7)
PART - A

M
1. Who is a mechanical engineer?

A
2. List out the roles and responsibilities of a mechanical engineer.
G
3. List out the various sectors in which job opportunities
PA

available for mechanical engineer.

4. What are the roles of mechanical engineer in product design field?
IP

5. What are the types of materials?

TH

6. List out any five mechanical properties.

7. What is roll forging? Give its applications.
PA

8. What are the two types of metal joining processes? Give examples.
9. List out the common machine tools.
L

10. List the important parts of a lathe.

A

11. Write the principle of drilling.

K

12. Define CNC.

13. What are the types of belt drive?
14. List out the applications of chain drive.
15. List any four properties of lubricants.
16. What are the common methods of lubrication?
17. Define heat.
18. Classify I.C engines based on arrangement of cylinders.
19. What is battery electric vehicle?
20. What is solar cell?
Question Papers QP.1
 PART – B
21. (a) Describe the job of a mechanical engineer.
(b) Explain the scope and opportunities for mechanical engineer
in the following sectors : (a) Manufacturing (b) Logistics
(c) What are the scope and opportunities for mechanical engineer
in the field of Automobile and Materials management.

22. (a) Explain the various thermal properties of materials.

(b) Explain extrusion process with neat sketches.
(c) Write short notes on welding.

M
A
23. (a) Explain the construction and principle of operation of
G
upright drilling machine with a neat sketch.
PA

(b) Explain the construction and principle of operation of

IP

vertical milling machine with a neat sketch.

TH

(c) List out the applications of CNC system.

PA

24. (a) Write short notes on V-belt drive. List out its applications,
advantages and disadvantages.
L

(b) Explain rack and pinion gear drive with a sketch. State its
A

applications.
K

(c) Explain the ring oiler lubrication method with a sketch.

25. (a) Explain various modes of heat transfer. Give examples.

(b) Explain the working of a steam power plant with a line sketch.
(c) Explain the working of horizontal axis windmill with a sketch.

Question Papers QP.2

 BASICS OF MECHANICAL ENGINEERING
MODEL QUESTION PAPER - II
Time: 3 Hrs. Max. Marks : 100
[N.B: (1) Answer any 15 questions under Part – A.
All questions carry equal marks. (15 × 2 = 30)
(2) Answer all questions, choosing any two sub-
divisions from each question under Part – B. All
questions carry equal marks (5 × 14 = 70) (7+7)
PART - A

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1. Who is a mechanical engineer?

A
2. Describe the job of a mechanical engineer.
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3. List out the various sectors in which job opportunities
PA

available for mechanical engineer.

4. List out the roles of mechanical engineer in quality control?
IP

5. Differentiate: Ferrous and non-ferrous metals.

TH

6. List out any five mechanical properties.

7. List out the advantages of hot working.
PA

8. Give the difference between temporary and permanent joining.

9. List out the common machine tools.
L

10. List the important parts in a lathe.

A

11. List out the types of drilling machine.

K

12. Define CNC.

13. What are the types of belt drive?
14. List out the applications of chain drive.
15. List any four properties of lubricants.
16. What are the purposes of lubrication?
17. Define heat.
18. What are the major components in a four stroke petrol engine?
19. What is battery electric vehicle?
20. State the principle of nuclear power plant.
Question Papers QP.3
 PART – B
21. (a) What are the roles and responsibilities of a mechanical
engineer?
(b) Explain the scope and opportunities for mechanical
engineer in the following sectors :
(i) Design (ii) Maintenance and service
(c) What are the scope and opportunities for mechanical engineer
in the field of Automobile and Materials management.

22. (a) Briefly explain the important chemical properties of materials.

M
(b) Explain roll forging with a neat sketch.

A
(c) Explain : (i) Soldering (ii) BrazingG
PA

23. (a) Explain the construction and principle of operation of

upright drilling machine with a neat sketch.
IP

(b) With a neat sketch, describe the construction and

working of horizontal milling machine.
TH

(c) List out the applications of CNC system.

PA

24. (a) Describe the three types of flat belt drive. State its
applications.
L
A

(b) Describe bevel gear drive with a sketch. List out its
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applications.
(c) With a sketch, explain the drip feed lubrication method.

25. (a) Explain various modes of heat transfer. Give examples.

(b) Explain the working of a steam power plant with a line
sketch.
(c) Explain the working of horizontal axis windmill with a
sketch.

Question Papers QP.4

 BASICS OF MECHANICAL ENGINEERING
BOARD EXAMINATION, APRIL - 2024
Time: 3 Hrs. Max. Marks : 100
[N.B: (1) Answer any 15 questions under Part – A.
All questions carry equal marks. (15 × 2 = 30)
(2) Answer all questions, choosing any two sub-
divisions from each question under Part – B. All
questions carry equal marks (5 × 14 = 70) (7+7)
PART - A

M
1. Define manufacturing.
2.
A
What is the importance of Logistics in mechanical engineering?
G
3. Write any four automotive industries in India.
PA

4. Define quality.
5. Write the types of engineering materials.
IP

6. Define hot working.

TH

7. Differentiate temporary and permanent joints.

8. What is brazing?
PA

9. What is the principle of lathe?

10. Define CNC.
L

11. Write the applications of CNC system.

A

12. List the types of drilling machines.

K

13. List the types of belt drives.

14. Draw the cross section of V - belt.
15. What is a cam drive?
16. List any four solid lubricants.
17. List the types of heat transfer.
18. Define ignition.
19. Give any two electric car models in India.
20. Define heat.

Question Papers QP.5

 PART – B
21. (a) Explain the roles and responsibilities of a mechanical
engineer .
(b) Explain the scope and opportunities of a mechanical engineer.
(c) Describe the 5 R's of material management.

22. (a) Explain the various chemical and thermal properties of

materials.
(b) Explain the working of a drop hammer with a neat sketch.

M
(c) Explain about various temporary joints.

A
G
23. (a) Draw a neat sketch of a lathe and label its parts.
PA

(b) Explain the components of a CNC system with neat sketch.

IP

(c) Compare vertical milling machine and horizontal

milling machine.
TH
PA

24. (a) Explain about helical gear drive and bevel gear drive.
(b) Mention the purpose of lubrication. List the properties
L

of lubricants.
A

(c) Explain grease cup lubrication with neat sketch.

K

25. (a) Explain the working of four stroke petrol engine with
neat sketch.
(b) Explain about horizontal axis wind mill.
(c) Draw the layout of a battery electric vehicle (BEV) and
explain its main components.

Question Papers QP.6

 BASICS OF MECHANICAL ENGINEERING
BOARD EXAMINATION, OCTOBER - 2024
Time: 3 Hrs. Max. Marks : 100
[N.B: (1) Answer any 15 questions under Part – A.
All questions carry equal marks. (15 × 2 = 30)
(2) Answer all questions, choosing any two sub-
divisions from each question under Part – B. All
questions carry equal marks (5 × 14 = 70) (7+7)
PART - A

M
1. Who is a Mechanical Engineer?

A
2. Write down any two roles of a Mechanical Engineer in
G
power generation.
PA

3. Write down the importance of maintenance in industries.

4. List out any two functions of a Mechanical Engineer in logistics.
IP

5. Name any two types of engineering materials.

TH

6. What is meant by extrusion?

7. Write about wire drawing.
PA

8. write any two examples for permanent joint.

9. Name any tow parts of lathe.
L

10. Write down the purpose of using coolant in drilling process.

A

11. Name any tow parts of horizontal milling machine.

K

12. Mention any two applications of CNC.

13. Write down the applications of rope drives.
14. Write any two differences between spur and helical gear.
15. Name the types of lubricants.
16. Write down the purpose of lubrication.
17. List out any four parts of Diesel engine.
18. Mention the benefits of battery electric vehicles.
19. Define conduction heat transfer.
20. Write any two differences between vertical and horizontal windmill.
Question Papers QP.7
 PART – B
21. (a) Discuss about the roles and responsibilities of
Mechanical Engineers in manufacturing sector.
(b) Discuss about the scope and opportunities of Mechanical
Engineers in automobile sector.
(c) Discuss about the roles and responsibilities of
Mechanical Engineers in materials management.

22. (a) Write about only seven mechanical properties of steel.

(b) Explain about the working of Mechanical press with neat

M
sketch.

A
(c) Draw and explain about temporary joints with examples.
G
PA

23. (a) Explain the working principle of lathe with neat sketch.
IP

(b) Explain the working of upright drilling machine with

TH

neat sketch.
(c) Explain the working of vertical milling machine with
PA

neat sketch.
L

24. (a) Explain about V-belt drive with neat sketch.

A

(b) Explain about worm and worm wheel drive with neat
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sketch.
(c) List out the methods of lubrication and explain any one.

25. (a) Draw the simple layout of steam power plant and
explain.
(b) Explain the working of four stroke petrol engine with
neat sketches.
(c) Explain about solar power plant with neat sketch.

Question Papers QP.8