With my personal experience, I have observed that,

usually, questions in the interviews are taken keeping in

mind for certain aspects and reasons,
Company Profile
Requirement of Profile
Relevance with past experience
Possible relation between Experience and Profile.
Expected knowledge to suit profile requirements.
Personal Interest and relevant Knowledge.
If freshers are encountered, then company looks for
flexibility in knowledge and adaptability.
Frequently Asked Questions
(FAQs) in Interviews


1) How to decide the power of Hydraulic Cylinder when it has to lift a
load of 200 kg vertically up. Mention the factors involved to calculate.
Answer.
2) Basic values of Sheet and Wire Gauge (SWG) to millimetre (mm).
Answer.
8 SWG 4mm
10 SWG 3.2 mm
14 SWG 2.01 mm
15 SWG 1.8 mm
16 SWG 1.6 mm
17 SWG 1.4 mm
18 SWG 1.2 mm
19 SWG 1.02 mm
20 SWG 0.9 mm
21 SWG 0.8 mm
22 SWG 0.7 mm
23 SWG 0.6 mm
3) Load Calculation (Stress and Strain) of Mechanical Structures (Point
Loads and Truss Members)
Answer.
Usually we have load calculations done on regular formulae,
= PL / AE or = P/ A
Where,
= Stress induced on the member.
P = Load mounted over
L = Span between supports.
A = Cross-sectional Area.
E = Youngs Modulus of the Material.
Now, certain basic Conditions for to calculate the deflections under various loading
conditions:
Here,
Y = Deflection in beam.
P = Load mounted over.
I = Inertia of the body.
x = Length between one support and the load concentration.

Rigid support, Cantilever, Point Loading.
Y = P / 6EI (2L
3
3L
2
x + x
3
)
Y
max
= PL
3
/ 3EI at x = 0.
Where, P = Point Load., L = Length of Span.


Rigid support, Cantilever, Uniform Loading.
Y = W / 24EI (3L
4
4L
3
x + x
4
)
Y
max
= WL
4
/ 8EI at x = 0.
Where, W = Product of total load(w) and length(L), I = Moment of Inertia.


Simply supported, Point Loading, Loading at centre.
Y = P / 48EI (3L
2
x - 4x
3
)
Y
max
= PL
3
/ 48EI at x = L/2.


Simply supported, Uniform Loading.
Y = - Wx / 24EI (L
3
2L x
2
+ x
3
)
Y
max
= - 5WL
3
/ 384EI at x = L/2.


Rigid supported, Centre point Loading.
Y = - P / 48EI (3Lx
2
- 4x
3
)
Y
max
= - PL
3
/ 192EI at x = L.


Rigid supported, Uniform Loading.
Y = Wx
2
/ 24EI (2Lx L
2
x
2
)
Y
max
= WL
3
/ 384EI at x = L/2.
4) Moment of Inertia for basic shapes.
Answer.

5) Calculation for Cutting / Shearing / Stripping / punching Force in
metals.
Answer.
If,
S = Thickness of Material.
L = Perimeter of cutting
A = L x S = Area of Shearing.

B
= Shear Strength (Constant value for every material).
Then,
Force (in Kg) = A x
B
6) Calculation for unbent / development length of sheet Metal.
Answer.

For a condition above we follow an easy and handy method to calculate the unbent
length required for the sheet. This method is only applicable for right angle bends with
same radius throughout and exterior dimensions mentioned. This is always clear that,
the inner radius of the bend is equal to the thickness of the sheet. Similarly, outer
radius of the bend is always the sum of the inner radius and the thickness of the sheet.
Now, for this method,
Unbent length = Total outer linear Length + (Product of Correction Factor and no. of
bends) (Product of Outer radius and no. of bends).
Table for Correction Factor:
Ratio (R/s) 5.0 3.0 2.0 1.2 0.8 0.5
Correction
Factor
1.0 0.9 0.8 0.7 0.6 0.5

Firstly, the ratio of Outer radius(R) of Bend and thickness of sheet(s) has to be
calculated, which will give ratio value to follow. Then corresponding to the ratio we
can pick the correction factor from the table above.
For the case above,
Total Linear Length = 50 + 100 + 50 = 200mm.
Outer Radius (R) = 20mm
No. of Bends = 2
Ratio = 20 / 10 = 2
Correction factor (q) corresponding to Ratio = 0.8
Therefore,
Unbent Length = 300 + (0.8 x 2) (20 x 2) = 261.6mm.
Note: - if the correction factor is not known, then a tolerance of 0.5mm should be
added at both the end of the sheet.
The other way is more flexible and can be used widely.

Here, the formula is,
L = { a + (R
1
+ q
1
x s/2)(
1
/180) } + { b + (R
2
+ q
2
x s/2)(
2
/180) } + ..... + ending linear
length.
Here till 120, we take smallest angle in the bend. Bends greater than 120, we take
exterior angles.
a = 70mm, b = 100mm, c = 100mm, R
1
= 30mm, R
2
= 20mm, s = 10mm, q
1
=

0.9, q
2
=

0.8,

1
=
2
= 90.
Hence, Unbent Length (L) = {70 + (30 + 0.9 x 10/2)( x 90/180)} + {100 + (20 + 0.8 x
10/2)( x 90/180)} + 100 = 124.19 + 194.77 + 100 = 418.96mm
Note: - In the above method there is a possibility of wastage of material if the bends
are not equal to 90 throughout.
7) Calculation for Radial Centripetal Force (RCF) for rorating
Equipments.
Answer.
The formula is as under;
RCF (g force) = {1.118 x (RPM)
2
x (R/100)} / 10
5
Where,
RCF = Centripetal force in Newtons.
RPM = Revolutions per minute.
R = Radius of string from the centre.
8) Specification of Pipes, tubes and their Uses used in petrochemical /
oil / process industries.
Answer.
9) Highlights of ASME Y 14.5M Standard for GD&T.
Answer.

10) Highlights of ASME Standards of 31.1 and 31.3.
Answer.
11) Types of Measuring System and their least counts.
Answer.
Verneir Calliper :- 0.02mm
Screw Gauge :- 0.01mm
Dial Verneir :- 0.02mm
Micrometer :- 0.01mm
Dial Bore Gauge :- 0.001 to 0.01mm
12) Classify Boilers with specifications.
Answer.
The classification of boilers is widely based on;
According to the flow of water and hot gases
i. Fire (smoke) Tube Boilers.
In fire tube boilers, hot gases pass through tubes which are surrounded with water.
Examples: Vertical, Cochran, Lancashire and Locomotive boilers.
ii. Water Tube Boilers.
In water tube boilers, water circulates through a large number of tubes and hot gases
pass around them. Eg, Bobcock & Wilcox boiler.
According to axis of Shell
i. Vertical Boilers.
The vertical boilers are boilers which are mounted vertically up-straight.
ii. Horizontal Boilers.
The horizontal boilers are boilers which are laid down horizontally rigidly supported by
a boiler bed.
According to position of furnace.
i. Internally Fired Boilers.
In internally fired boilers, the furnace forms an integral part of the boilers structure.
The vertical tubular, locomotive and the scotch marine boilers are well known
examples.
ii. Externally Fired Boilers.
Externally fired boilers have a separate furnace built outside the boiler shell and usually
below it. The horizontal return tube (HRT) boiler is probably the most widely known
example of this type.
According to the application and use.
i. Stationary Boilers.
Stationary boilers are one of which is installed permanently on a land installation.
ii. Mobile Boilers.
A marine boiler is a mobile boiler meant for ocean cargo and passenger ships with an
inherent fast steaming capacity.
According to the steam pressure.
i. Low pressure Boilers.
ii. Medium pressure Boilers.
iii. High pressure Boilers.
13) Mention Auxiliaries used in Boilers.
Answer.
14) Types of Power generation.
Answer.
Thermal Power Generation
1. Fossil Fuels
I. Coal
II. Petroleum
III. Natural Gas
2. Solar Thermal Energy
3. Geothermal Energy
4. Nuclear Energy
Hydroelectric Power Generation
Wind Power Generation
Solar Power Generation
Chemical Power Generation
1. Fuel Cells
2. Batteries
15) Relation between Current, Voltage and Resistance.
Answer.
The relation between current, voltage and resistance is well explained in Ohms law.
According to Ohms Law, Voltage (V) is directly proportional to Current (I), where
Resistance (R) remains constant. In other words, Voltage is a product of Current and
the Resistance. Mathematically,
V = IR
16) Classification of Turbine.
Answer.
17) How to classify and measure values for Wire, Cable, and Bus Bar.
Answer.
18) Formulas of Series and Parallel Connection.
Answer.
19) Define Alpha and Delta Connection and differentiate them.
Answer.
20) Difference between Relay and Switch.
Answer.
Relays are a form of a switch that can be actuated without any human intervention.
They most often are active devices that must be plugged in to operate. Relays are used
on high current values with no limits.
Switches are rated for certain load limits, so it has to be sure about use of appropriate
switch especially if the switch is being used on an amplified level circuit. Switches are
bound to current values to operate.
21) Types of Motors and their Specification.
Answer.
Electric Motors are broadly classified as under;
i. DC (Direct Current) Motors.
Disadvantages of DC Motor are,
Since they need brushes to connect the rotor winding. Brush wear occurs,
and it increases dramatically in lowpressure environment. So they cannot
be used in artificial hearts. If used on aircraft, the brushes would need
replacement after one hour off operation.
Sparks from the brushes may cause explosion if the environment contains
explosive materials.
RF noise from the brushes may interfere with nearby television sets, or
electronic devices, etc.
a. Shunt Motor.
In Shunt Motor the rotor and stator windings are connected in parallel.
b. Separately Excited Motor.
In Separately Excited Motor the rotor and stator are each connected from a different
power supply; this gives another degree of freedom for controlling the motor over the
shunt.
c. Series Motor.
In series motor the stator and rotor windings are connected in series. Thus the torque is
proportional to square of current,

so it gives the highest torque per current ratio over
all other dc motors. It is therefore used in starter motors of cars and elevator motors.
d. Permanent Magnet DC Motor (PMDC).
In PMDC motors, the stator is a permanent magnet, so the motor is smaller in size. But,
it can be only used for low torque applications.
e. Compound Motor.
In compound Motors, the stator is connected to the rotor through a compound of shunt
and series windings, if the shunt and series windings add up together, the motor is
called cumulatively compounded. If they subtract from each other, then a differentially
compounded motor results, which is unsuitable for any application.
ii. AC (Alternating Current) Motors.
a. Induction Motor.
The Induction Motor is so called because voltage is induced in the rotor (thus no need
for brushes), but for this to happen, the rotor must rotate at a lower speed than the
magnetic field to allow for the existence of an induced voltage. Therefore a new term is
needed to describe the induction motor: The slip.
b. Synchronous Motor.
The Synchronous Motor is so called because rotor tries to line up with the rotating
magnetic field in the stator. It has the stator of an induction motor, and the rotor of a
dc motor.
iii. Other Motors.
a. Reluctance motor
A Reluctance Motor is like a synchronousinduction motor. The rotor has salient poles
and a cage so that it starts like an induction motor, and runs like a synchronous motor.
b. Hysteresis motor
The Hysteresis motor uses its own hysteresis producing the torque, which can be can be
very tiny and are used as the driver for electric clocks.
c. Stepper Motor.
A Stepper motor is a special type of synchronous motors which rotates a number of
degrees with each electric pulse.
d. Brushless DC Motor.
A Brushless DC Motor is a close cousin of a permanent magnet stepper motor with
electronic controllers.
e. Universal Motor.
If a series DC motor has a laminated stator frame, it can run effectively from an ac
supply as well as dc, this is the Universal Motor.
22) Classify Pumps.
Answer.
Pumps can be broadly classified as under,
Positive Displacement Pumps.
In a positive displacement pumps, energy is periodically added to the liquid by the
direct application of force to one or more movable volumes of liquid. This cause an
increase in pressure up to the value required to move the liquid through ports in the
discharge line. This is more visible in Reciprocating Pumps.
i. Reciprocating Pumps.
ii. Blow Case Pumps.
iii. Rotary Pumps.
Kinetic / Dynamic Pumps.
In a kinetic pump, energy is continuously added to the liquid to increase its velocity.
When the liquid velocity is subsequently reduced, this produces a pressure increase.
Although there are several special types of pumps that fall into this classication, for
the most part this classication consists of centrifugal pumps.
i. Centrifugal Pumps.
ii. Regenerative Pumps.
iii. Special Effect.
Others, viz; Buoyancy, impulse, etc.
23) Classify Reciprocating Pumps.
Answer.
Reciprocating Pumps are broadly classified as under;
iv. Air operated reciprocating Pumps.
f. Diaphram Air operated reciprocating
Pumps.
g. Bellows Air operated reciprocating Pumps.
h. Piston Air operated reciprocating Pumps.
v. Steam reciprocating Pumps.
c. Horizontal Steam reciprocating Pumps.
d. Vertical Steam reciprocating Pumps.
vi. Power reciprocating Pumps.
a. Horizontal Power reciprocating Pumps.
b. Vertical Power reciprocating Pumps.
vii. Controlled Volume reciprocating Pumps.
a. Horizontal Controlled Volume
reciprocating Pumps.
b. Vertical Controlled Volume reciprocating
Pumps.
24) Classify Rotary Pumps.
Answer.
Rotary Pumps Rotary pumps are pumps in which displacement is done by gears, cam
or vanes in a chamber of diaphragm in a fixed casing. Rotary pumps are classified as
under.
Vane Rotary Pumps.
i. Blade, bucket roller Vane Rotary Pumps.
ii. Slipper Vane Rotary Pumps.
Piston Rotary Pumps.
i. Axial Piston Rotary Pumps.
ii. Radial Piston Rotary Pumps.
Flexible member Rotary Pumps.
i. Flexible tube Rotary Pumps.
ii. Flexible vane Rotary Pumps.
iii. Flexible liner Rotary Pumps
Lobe Rotary Pumps.
i. Single Lobe Rotary Pumps.
ii. Multiple Lobe Rotary Pumps.
Gear Rotary Pumps.
i. Internal Gear Rotary Pumps.
ii. External Gear Rotary Pumps.
Circumferential Piston Rotary Pumps.
i. Single Circumferential Piston Rotary Pumps.
ii. Multiple Circumferential Piston Rotary Pumps.
Screw Rotary Pumps.
i. Single Screw Rotary Pumps.
ii. Multiple Screw Rotary Pumps.
25) Classify Centrifugal Pumps.
Answer.
Centrifugal Pumps - Centrifugal pumps are used in more industrial applications than
any other kind of pump. This is primarily because these pumps offer low initial and
upkeep costs.
Traditionally these pumps have been limited to low-pressure-head applications, but
modern pump designs have overcome this problem unless very high pressures are
required.
The single-stage, horizontal, overhung, centrifugal pump is by far the most commonly
type used in the chemical process industry. Centrifugal Pumps were classified perfectly
in (American Petroleum Institute) API 610 technically equivalent to ISO 13709. They
are broadly classified as:
Overhung Centrifugal Pumps.
A pump with the impeller(s) cantilevered from its bearing assemblies is classified as
overhung pumps.
a) Flexibly Coupled
(1) Horizontal
i. Foot Mounted OH1
ii. Centreline Supported OH2
(2) Vertical In-line with Bearing Bracket OH3
b) Rigidly Coupled
(1) Vertical In-line OH4
c) Close Coupled
(1) Vertical In-line OH5
(2) High Speed integrally geared OH6

Between Bearings Centrifugal Pumps.
A pump with the impeller(s) located between the bearings is classified as between
bearing pumps. A pump may be single stage, two stage or multistage. It can be axially
(horizontally) split or radially split.
(1) 1
st
and 2
nd
stage
i. Axially Split BB1
ii. Radially split BB2
Vertically Suspended Centrifugal Pumps.
A pump with the impeller(s) cantilevered vertically and the suction nozzle typically
submerged is classified as vertically suspended pump.
(1) Single Casing
i. Discharge through column
Diffuser VS1
Volute VS2
Axial Flow VS3
ii. Separate Discharge
Line-shaft VS4
Cantilever VS5
(2) Single Casing
i. Diffuser VS6
ii. Volute VS7
Seal-less Centrifugal Pumps.
Seal-less pumps are special pumps which do not require shaft seals. Construction for
seal-less pumps is driven by canned motors or magnetic couplings. It is normally used in
process involving extreme hazardous fluid, where leakage cannot be tolerated.
Submersible Centrifugal Pump.
Submersible Pumps are designed to prevent cavitations. The driver components inside
are completely surrounded by the pumped fluid.
Horizontal self-priming Centrifugal pump.
Horizontal self-priming pump are designed to create a vacuum at the pump inlet. This
enables the pump to suck fluid into its casing. The suction nozzle of the pump can
therefore be located above the level of liquid being pumped.
Pumps shall be capable of operating at the maximum continuous speed. The maximum
continuous speed is defined as,
Equal to synchronous speed at maximum supply frequency of electrical motors.
At least 105% of rated speed for variable speed pumps capable of exceeding
rated speed.
26) Highlights / similarities in API 610 and ISO 13709.
Answer.
The deflection () is measured in terms of Shaft Flexibility Index (SFI), occurred by load
(w),

I
SF
= {(L
1
3
/ D
1
4
) + (L
1
2
L
2
/ D
1
4
)}
But, since the second part of equation above contributes only 20% of the actual value
of SFI (Shaft Flexibility Index) abbreviated as I
SF.

Hence,
I
SF
= (L
1
3
/ D
1
4
)
Generally, the lower the SFI number for an overhung process, better is the shaft
stiffness, thus giving higher Mean time between Repair (MTBR).
There is other factor called pump sizing factor,
K
t
= QH / N
Where,
Q = Flow Rate
H = Head at flow rate
N = Rotating speed
For efficient motor;
Higher point of graph should lie between

10 < I
SF
< 10
2

1 < K
t
< 10

Lower point of graph should lie between

10
-3
< I
SF
< 10
-2

10
4
< K
t
< 10
5

Applying the new formula with standards, it is found that the system life of bearings is
shorter than the shortest life of individual bearing.
Three ways of torsional analysis;
i. Undamped Natural Frequency.
ii. Steady State damped response analysis
iii. Transient Torsional
A head drop of 3% is allowable at the maximum at the first stage termed as NPSH3.
Note: - Old overhung rotor designs have SFI value of 300 or even 1000. SFI of 50 is
really fine.
The bearing life as per API should be at 25000 hours at continuous run and if rated for
conditions, bearing life should be 16000 hours at maximum axial and radial load at
rated speed. This bearing life applies to the system bearing life.
Formula, for bearing system life,
L
10
= {(1 / L
10hA
)
3/2
+ (1 / L
10hB
)
3/2
+ ..... + (1 / L
10hN
)
3/2
}
-2/3

Where,
L
10hA
= Basic rating life L
10h
as per ISO 281 for bearing A.
L
10hB
= Basic rating life L
10h
as per ISO 281 for bearing B.
L
10hN
= Basic rating life L
10h
as per ISO 281 for bearing N.
N = Number of Bearings.
Note:- Non-metallic cages shall not be used.
27) Specification of Turbines.
Answer.
28) Types of Flow with relation.
Answer.
29) Explain terms used in Psychrometric Chart.
Answer.
30) Transformer types and Specification.
Answer.
A transformer is an apparatus for converting electrical power in an ac system at one
voltage or current into electrical power at some other voltage or current without the
use of rotating parts.
In general, transformers are used for two purposes: signal matching and power
supplies.
Power Transformers
Power transformers are used to convert from one voltage to another, at significant
power levels.
Step-up Transformers
A "step-up transformer" allows a device that requires a high voltage power supply to
operate from a lower voltage source. The transformer takes in the low voltage at a
high current and puts out the high voltage at a low current.
Step-down Transformers
A "step-down transformer" allows a device that requires a low voltage power supply to
operate from a higher voltage. The transformer takes in the high voltage at a low
current and puts out a low voltage at a high current.
Isolation Transformers
An "isolation transformer" does not raise or lower a voltage; whatever voltage comes
in is what goes out. An isolation transformer prevents current from flowing directly
from one side to the other. This usually serves as a safety device to prevent
electrocution.
Variable Auto-Transformers
A "variable auto-transformer" (variac) can act like a step-up transformer or step-down
transformer. It has a big knob on top that allows you to dial in whatever output voltage
you want.
Poly-phase Transformers
This type of transformer is commonly associated with three phase electric power,
which is a common method of transmitting large amounts of high voltage power, such
as the national power grid. In this system, three separate wires carry alternating
currents of the same frequency, but they reach their peak at different times, thus
resulting in a continuous power flow. Occasionally these three-phase systems have a
neutral wire, depending on the application. Other times, all three phases can be
incorporated into one, multiphase transformer. Winding patterns can vary and so can
the phases of a poly-phase transformer.
Leakage Transformer
Leakage transformers have a loose binding between the primary and secondary
winding, which leads to a large increase in the amount of inductance leakage. All
currents are kept low with leakage transformers, which help prevent overload. They
are useful in applications such as arc welding and certain high-voltage lamps, as well as
in the extremely low-voltage applications found in some childrens toys.
Resonant Transformer
As a type of leakage transformer, resonant transformers depend on the loose pairing
of the primary and secondary winding, and on external capacitors to work in
combination with the second winding. They can effectively transmit high voltages, and
are useful in recovering data from certain radio wave frequency levels.
Audio Transformer
Originally found in early telephone systems, audio transformers help isolate potential
interference and send one signal through multiple electrical circuits. Modern
telephone systems still use audio transformers, but they are also found in audio
systems where they transmit analog signals between systems. Because these
transformers can serve multiple functions, such as preventing interference, splitting a
signal, or combining signals, they are found in numerous applications. Amplifiers,
loudspeakers, and microphones all depend on audio transformers in order to properly
perform.
31) Classify Transformers.
Answer.
According to method of Cooling
a) Self-aircooled (dry type)
b) Air-blastcooled (dry type)
c) Liquid-immersed, self-cooled
d) Oil-immersed, combination self-cooled and air-blast
e) Oil-immersed, water-cooled
f) Oil-immersed, forced-oilcooled
g) Oil-immersed, combination self-cooled and water-cooled
According to insulation between windings
a) Windings insulated from each other
b) Auto transformers
According to No. of Phases
a) Single-phase
b) Poly-phase
According to Method of Mounting
a) Pole and platform
b) Subway
c) Vault
d) Special
According to purpose
a) Constant-voltage
b) Variable-voltage
c) Current
d) Constant-current
According to service
a) Large power
b) Distribution
c) Small power
d) Sign lighting
e) Control and signalling
f) Gaseous-discharge lamp transformers
g) Bell ringing
h) Instrument
i) Constant-current
j) Series transformers for street lighting
32) Cost Estimation and Analysis.
Answer.
33) Areas, Volumes and Perimeter formulas of all basic Geometric Shapes.
Answer.
34) Hole Fit Precision to define tolerances.
Answer.
H5 Grinding, Honing (Fine Surface Finish)
H6 Grinding, Boring (Fine Surface Finish)
H7 Internal Operations like reaming, drilling, boring, etc (Normal Surface
Finish)
H8 Machining (Normal Surface Finish)
H9 Boring and Reaming (Coarse Surface Finish)
H10 / H11 Coarse Running (No Diameters)
35) Running Fit tolerances (Tolerances between two running machine
parts).
Answer.

Precision Running Fit
H6 / g5
H7 / g6
H8 / g7
Close Running Fit
H6 / f5
H7 / f6
H8 / f7
Normal Running Fit
H6 / e5
H7 / e6
H8 / e7
Loose Running Fit
H6 / d5
H7 / d6
H8 / d7
Slack Running Fit
(Fine Surface Finish)
H8 / c5
H8 / b6
H9 / a8
(Normal Surface Finish)
H9 / c9
H11 / c9
(Coarse Surface Finish)
H11 / c11
H11 / b11
H11 / a11
36) Non-Running Fit tolerances (Tolerances between two fixed non-
running machine parts).
Answer.
Precision Running Fit
H6 / h5
H6 / h6
Close Running Fit
H7 / h6
H7 / h7
Normal Running Fit
H8 / h7
H8 / h8
Loose Running Fit
H9 / h8
H9 / h9
Slack Running Fit
H11 / h9
H11 / h11
37) Transitional Fit tolerances (Tolerances between two machine parts
which are connected to stay fixed in a moving assembly).
Answer.
Clearance Running Fit
H6 / j5
H7 / j6
H8 / j7
True Transitional Fit
H6 / k5
H7 / k6
H8 / k7
Interface Fit
H6 / m5
H7 / m6
H8 / m7
Press Fit
H6 / p5
H7 / p6
Medium Drive Fit
H6 / r5
H7 / r6
Semi-Permanent drive Fit
H6 / s5
H7 / s6
Shrink / Permanent Fit (Shrinks are made in parts by heating)
H6 / u5
H7 / u6
38) Types of Gears and its features.
Answer.
Advantages of Gears over other drives:-
1. The gear has a positive drive and a constant velocity ratio. The velocity ratio is
the ratio of effort used to the distance travelled.
Velocity Ratio = (Effort Used to move / Distance Travelled)
2. The gear drive can transmit at very low velocities which is not possible in belt
drives.
3. The efficiencies of the gear drives are very high.
4. The gear drives consumes very less space for assembly.
The gears are widely classifies as:-
1. Spur Gears; are gears in which teeth are cut parallel to the axis of shaft. These
gears impose radial loads on the shaft.
2. Helical Gears; are gears in which teeth are cut at an angle to the axis of shaft. .
These gears impose radial and thrust loads on the shaft.
3. Bevel Gears; are used where shafts are aligned to right angles. The teeth of the
spiral gear are cut straight or spiral. These gears impose radial and thrust loads
on the shaft.
4. Worm Gears; consist of a threaded screw and a matching wheel. The thread may
be single or multistart. The worm gear induces high thrust loads while the other
induces high radial loads.
39) Types of Gears Trains.
Answer.
1. Simple Gear Train; which carries only one gear in a shaft.
Velocity Ratio (n
1
/n
4
) = (z
4
/z
1
)
2. Compound Gear Train;
Velocity Ratio (n
1
/n
4
) = (z
2
/z
1
) (z
4
/z3)
3. Reverted Gear Train; the centre distance of gears 1 and 2 are same and gears 3
and 4 have the same centre distance.
Velocity Ratio (n
1
/n
4
) = m
1
(z
1
+ z
2
) = m
1
(z
3
+ z
4
)
4. Epicyclic Gear Train; is an arrangement with sun and planet system.
Idler Gear is a gear, which operates between two main shaft gears. If the no. of idler
gears in a gear train is even (even zero), then the first and last gears rotate in the
opposite gears.
Similarly if the no. of idler gears in a gear train is odd, then the first and the last gear
rotate in the same direction.
40) Basic formula for Spur Gears.
Answer.
Let us first understand the terms;
Pitch Circle Diameter (d = mz)
Circular Pitch (p = d/z)
Diameteral Pitch (P = z/d)
Addendum Circle Diameter {d
a
= m(z + 2)}
Addendum (A = M)
Deddendum (D = 1.25M)
Deddendum Circle Diameter {d
f
= m(z - 2.5)}
Tooth Thickness 1.5708M
Bottom Clearance 0.25M
Centre Distance {C = m(z
P
+ z
G
) / 2}
No. of Teeth (Z = 2 / sin
2
), where is the pressure angle.
41) How to calculate shear stress in Bolts.
Answer.
Bolts and other types of connectors in structures undergo forces as the structures are
loaded and unloaded. One of the forces that affect bolts is shear stress. When a bolt
connects two or more parts, each of the parts can impart separate forces on the bolt,
often in different directions. The result of these opposing forces on the bolt is shear
stress at the plane through the bolt between the two connected components. If the
shear stresses in the bolt are too high, then the bolt can break.
An extreme example of shear is the use of bolt cutters on a bolt. The two blades of the
cutters impart opposite forces on a single plane of the bolt, resulting in a cut bolt.
Determining the shear stress in a bolt is a straightforward calculation using only a few
inputs.
Procedure to calculate Shear Stress in Bolts;
Use the ruler or digital callipers to measure the thickness of each part of the
bolted assembly. Label each thickness t1, t2, t3, and so on.
Calculate the shear stress using the formula, = F/(d*(t1+t2)) if the bolt connects
two plates where each plate is subjected to a force (F) in opposite directions.
This load case is called single shear. For example, if two plates with 1-inch
thicknesses are connected by a bolt with a diameter (d) of 1 inch, and each plate
is subjected to a force of 100 lb, then it equals to 50 psi.
Calculate the shear stress using the formula = F/(2d*(t1+t2+t3)) if the bolt
connects three plates, where the centre plate experiences a force in one
direction and the other two plates experience a force in the other direction. This
load case is considered double shear because shear occurs in two different
planes in the bolt. For example, if three plates with 1-inch thicknesses are
connected by a bolt with a diameter (d) of 1 inch, and the plates are subjected
to a force of 100 lb, then it is equal to 16.7 psi.
42) The old welding machines used electromagnetic winding to step up the
current for welding rods. What is the new principle inside the welding
machines?
Answer.
The new principle inside the welding machine is based on the metal-arc welding. When
one side of the welding circuit is connected to a piece of steel, an arc will be formed
when a welding electrode attached to the other side and the two brought into contact.
When the electrode is transferred along the steel at an accurate speed, the metal will
deposit in an even layer known as a bead. Regulating the power is important in order
to make use of these principles in metal-arc welding.
43) What can be the reasons for a metal gasket to leak?
Answer.
Metal Gaskets may leak due to high pressures, temperature deformations, chemical
reactions if any, or wear outs of Rubber, metal or both in the Gasket.
44) In order to ensure constant pressure and constant flow rate of
compressed air what should we put between the compressor and end
user?
Answer.
Air Receiver is associated with a storage tank is used to serve the purpose end to avoid
the return stroke of air in the compressor.
45) What are the different types of mechanism to engage primary moving
engine and transmission (in other words how many different types of
clutches are there)?
Answer.
Dog Clutches, Cone Clutch, Friction Clutch, Safety Clutch, Hydraulic Clutch,
Electromagnetic Clutch, Centrifugal Clutch, Over-running Clutch.
46) Instead of having individual transmission what is the benefit of unified
transmission?
Answer.
It controls the active and reactive power flows in the same transmission line.
47) What is a torque converter?
Answer.
A torque converter acts like a clutch in an automobile which separates the load(fluid
pressure) from the power source.
48) Oil melts, grease melts. Is there any other lubrication which is effective
at 200 deg c?
Answer.
Materials like Nylon, Derlin, etc may be a suggestion. Apart from that synthetic
lubricants and high performance thickners are an option.
49) If any machinery or transmission needs periodic and regular
lubrication what is the best method to give it?
Answer.
Automatic Lubrication methods can be done by mechanizing systems. Alternatively, we
can know the oil deterioration rates and can maintain lubrication.
50) In which industrial process you will use centrifugal separator?
Answer.
They are used in Environmental Processes, Water Purification, Oil Purification
processes, Dairy Processes.
51) When mesuring the flow of liquid what are the things to be known?
Answer.
Density, Area and Velocity.
52) How to calculate shear strength in Bolts.
Answer.
Shear stress is defined as the internal forces acting on an object when a force acts
parallel to the face of the material, whereas shear strength is the maximum force the
object can handle before becoming structurally compromised.
Calculating the shear strength of a bolt can be particularly important, especially during
construction work, as very large stresses can cause the bolts to fail.

Procedure to calculate Shear Stress in Bolts;
Multiply the failing force of the bolt (the maximum force the bolt can sustain
before failure) by 4. For example, if the failing force is 2 Newtons (N), then the
result will be 8 N. Call this result A.
Square the diameter of the circular component of the bolt, and multiply by the
constant pi (3.14159). For example, if the diameter of the bolt is 0.1 meters (m),
squaring gives 0.01 meters squared (m^2), and multiplying by pi gives 0.031459.
Call this result B.
Divide result A by result B. In our example, dividing 8 N by 0.0314159 gives 255
Pascals (Pa). This is the shear strength of the bolt.