TEST ID: 405

ACE
Engineering Academy
Hyderabad | Delhi |Bhopal | Pune | Bhubaneswar | Bengaluru | Chennai |
Vijayawada | Visakhapatnam | Tirupati

Mechanical Engineering
ESE CONVENTIONAL TEST – 5
Time Allowed: 3 Hours Maximum Marks: 200

INSTRUCTIONS
Please read each of the following instructions carefully before attempting
questions:
Candidates should attempt FIVE questions in all.
Question No.1 is compulsory. Out of the remaining FIVE questions attempt
any FOUR.

The number of marks carried by a part of a question is indicated against it.

Answers must be written in ENGLISH only.

Unless otherwise mentioned, symbols and notations have their usual

standard meanings.

Assume suitable data, if necessary and indicate the same clearly.

Neat sketches may be drawn, wherever required.

All parts and sub-parts of a question are to be attempted together in the

answer book.
Any pages left blank in the answer book must be clearly struck out.

[contd.]

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01(a). Name and discuss the factors that contribute to the

formation of
(i) discontinuous chip
(i) continuous chip with built up edge (10 M)

01(b). In drilling of 20 mm diameter hole in a M.S. solid

block of 25mm thickness, the feed rate used is 0.25
mm/rev. The drill must be changed after making 10
holes if it is rotated at 250 rpm. But the drill can
produce 50 holes if it is rotated at 200 rpm. How
many holes can be produced if its rpm is 150 ?
(10M)

01(c). The mean diameter of a cone clutch is 75 mm, the

semi-cone angle of it being 12.5. Assuming
coefficient of friction as 0.3, determine the minimum
torque required to produce slipping of the clutch, for
an axial force of 180 N. If the clutch is used to
connect an electric motor, with a stationary flywheel
of an engine, how much time is required to attain the
full speed. How much energy will be lost during
slipping motor speed is 960 rpm, and M.I of flywheel
is 0.5 kg-m2. (10M)
01(d).
(i) Derive the maximum acceleration of the follower
when it is following simple harmonic motion.
(7M)
(ii) How pressure angle influences the force exerted by a
cam on the follower. (3M)

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02(a). A journal bearing of 50 mm diameter and 80 mm

long, has a bearing pressure of 6 N/mm2. The speed of
the journal is 1000 rpm. The ratio of journal diameter
to the diametral clearance is 1000. The bearing is
lubricated with oil, whose absolute viscosity at the
operating temperature of 75C may be taken as 0.015
kg/m-s. The room temperature is 25C. Determine (i)
the amount of artificial cooling required, and (ii) the
mass of the coolant oil required, if the difference
between the outlet and inlet temperatures of the oil is
10C. The specific heat of the oil is 1900 J/kgC and
heat dissipation coefficient is 500 W/m2C.
(15M)

02(b). Sketch and explain the working of centrifugal clutch

give one application of it. (10M)

02(c). A seamless tube 32 mm outer diameter is turned on

the lathe. The cutting velocity of tool relative to
workpiece is 10 m/min. Rake angle,  =35, depth of
cut, t1 = 0.125 mm, length of chip = 60 mm.
Horizontal cutting force of the tool on workpiece =
200 N, vertical cutting force required to hold the tool
against work = 80 N. Calculate
1. Coefficient of friction
2. Chip thickness ratio
3. Shear plane angle
4. Velocity of chip relative to tool
5. Velocity of chip relative to workpiece
(15M)

3 [contd.]
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03(a). What is the fundamental mechanism of chip

formation? Some major tool materials are mentioned
below.

1. High speed steel 2. carbon steel

3. Ceramics 4. Tungsten carbides
5. cast alloys 6. CBN
7. Single crystal diamond.
Arrange these in terms of wear resistance and
toughness. What do you understand by High Speed
Steels and where they are used?
Write two material properties that affect
machinability. (20 M)

03(b). The following data relate to a cam profile in which the

follower moves with uniform acceleration and
deceleration during ascent and descent respectively.
Minimum radius of cam = 25 mm
Roller diameter = 7.5 mm
Lift = 28 mm
Offset of follower axis = 12 mm towards right
Angle of ascent = 60
Angle of descent = 90
Angle of dwell between ascent and descent = 45
Speed of the cam = 200 rpm
Draw the profile of the cam and determine the
maximum velocity and the uniform acceleration of the
follower during the outstroke and the return stroke.
(20M)

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04(a). Select a suitable ball-bearing subjected to following

loads:
Radial load of 600 kgf at 150 r.p.m. for 25% of time.
Radial load of 750 kgf at 600 r.p.m. for 20% of time.
Radial load of 200 kgf at 200 r.p.m. for 55% of time.
The loads are steady . The outer ring remains
stationary. The bearing has to bare an expected average
life of 2500 hours. The shaft diameter can be adjusted
to the bearing selected. The data given below may be
used.

No. Inner Outer Width Basic Dynamic Max.

SKF Dia. Dia. (mm) Static Capacity speed
(mm) (mm) load (kgf ) (rpm)
(kgf)
6007 35 62 14 880 1250 13000
6008 40 68 15 980 1320 10000
6009 45 75 16 1270 1630 10000
6010 50 80 16 1370 1700 8000
6011 55 90 18 1800 2200 8000
6012 60 95 18 1930 2280 8000
6013 65 100 18 2120 2400 8000
6014 70 110 20 2550 3000 6000
(15M)

04(b).
(i) State the conditions for complete balancing in an
automobile engine. (4M)
(ii) Show that inline four cylinder, 4-stroke engine is
completely balanced. (6M)

5 [contd.]
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04(c). In orthogonal machining prove that

r cos 
tan   c , where rc = chip thickness ratio,
1  rc sin 
 - Back rake angle,  = shear angle. State that
assumption made. Is it desirable to have high shear
angle? If so why? (15M)
05.(a). Following data were collected from an orthogonal
machining test on steel:
Cutting speed = 18 meters / minute
Rake angle = 20 degrees
Clearance angle = 10 degrees, Width of cut = 3.2 mm
Un-deformed chip thickness = 0.10 mm
Deformed chip thickness = 0.25 mm
Cutting force in the cutting velocity direction = 80 kgf
Normal force in a direction normal to cutting velocity
= 50 kgf
Draw the circle diagram of force and evaluate the
following:
Shear angle; Shear strain; Friction co-efficient against
chip flow; Friction force on the rake face.
(20 M)
05(b). In an open flat belt drive, the pulley diameter are 300
mm and 450 mm, and the corresponding angles of lap
are 160 and 200. The smaller pulley runs at 240
rpm. The coefficient of friction between the pulleys
and belt is 0.3. It is found that the belt is on the point
of slipping when 5 kW power is transmitted. To
increase the power transmitted; two alternatives are
suggested, viz., (i) increasing the initial tension by
15% and (ii) increasing the coefficient of friction by
15%. Which of the above two methods would be more
effective ? (20M)

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06(a). In V-engine, for a given value of  (angle between x-

axis and the centre line of the cylinder block), show
that resultant primary force is maximum, when the
crank angle () is zero. Explain with a neat sketch.
(20M)

06(b). Four masses A, B, C and D carried by a rotating shaft

at radii 85 mm, 100mm, 160mm and 125mm
respectively are completely balanced masses A, B and
C are 9 kg, 5 kg and 10 kg respectively. Determine the
mass and angular position of A, if the planes are
spaced 400 mm apart. Solve the problem using
graphical method.
(20M)

7 [contd.]
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SPACE FOR ROUGH WORK