Gate 2005

GA/QB/PI−IV Elite Academy 25
2005
PI : Production And Industrial Engineering
Duration: Three hours Maximum Marks : 150
Read the following instructions carefully
1. This question paper contains all objective questions. Q.1 to Q.30 carry one mark each
and Q.31 to Q.80 carry two marks each. Q. 81 to Q. 85 each contains part “a” and “b”.
In these questions, parts “a” as well as “b” carry two marks each.
2. Answer all the questions.
3. Questions must be answered on special machine gradable Objective Response Sheet
(ORS) by darkening the appropriate bubble (marked A, B, C, D) against the question
number on the left hand side of the ORS, using HB pencil. Each question has only one
correct answer. In case you wish to change an answer, erase the old answer completely
using a good soft eraser.
4. There will be NEGATIVE marking. In Q.1 to Q.30, 0.25 mark will be deducted for each
wrong answer and in Q.31 to Q.80, 0.5 mark will be deducted for each wrong answer. In
Q.81 to Q.85, for the part “a”, 0.5 mark will be deducted for a wrong answer. Marks for
correct answers to part “b” of Q.81 to Q.85 will be given only if the answer to the
corresponding part “a” is correct. However, there is no negative marking for part “b” of
Q. 81 to Q.85. More than one answer bubbled against a question will be deemed as an
incorrect response.
5. Write your registration number, name and name of the Centre at the specified locations
on the right side of the ORS.
6. Using HB pencil, darken the appropriate bubble under each digit of your registration
number and the letters corresponding to your paper code.
7. Calculator is allowed in the examination hall.
8. Charts, graph sheets or tables are not allowed.
9. Use the blank pages given at the end of the question paper for rough work.
26 Elite Academy GA/QB/PI−IV
Q.1 – Q.30 carry one mark each
1. Which one of the following is NOT associated with vector calculus?

(A) Stoke’s theorem (B) Gauss Divergence theorem
(C) Green’s theorem (D) Kennedy;s theorem
2. For solving algebraic and transcendental equations, which one of the following is
used?
(A) Coulomb’s theorem (B) Newton-Raphson Method
(C) Euler’s theorem (D) Stoke’s theorem
3 2
  dy  2   d2y 
3. The differential equation 1 +    = c 
2
 is of
  dx   2x
  
 d 
(A) second order and third degree (B) third order and second degree
(C) second order and second degree (D) third order and third degree
4. Newton-Raphson formula to find the roots of an equation f(x) = 0 is given by

[
(A) x n +1 = x n − f ( x n ) / f ′( x n ) ] (B) x n +1 = x n + [f ( x n ) / f ′( x n )]
(C) x n +1 = f ( x n ) / [ x n f ′( x n ) ] (D) x n +1 = x n [f ( x n ) / f ′( x n )]
5. The largest stress a material can withstand without any measurable permanent
strain on the complete release of load is
(A) proportional limit (B) elastic limit
(C) yield strength (D) ultimate tensile strength
6. In a screw jack, ACME thread of included angle 2α and lead angle λ is used. If
the thread friction is µ and the collar friction is zero, then the lowering torque is
minimum when
(A) µ < cos α. tan λ (B) µ = cos α. tan λ
(C) µ > cos α . tanλ (D) µ < cos α. tan λ

7. In the toggle mechanism of a stone crusher shown in the Fig. below, a force of
200 kN is applied at the slider. The instantaneous horizontal force available at
jaw R (in kN) for crushing the stone is
(A) 100 (B) 173 (C) 200 (D) 273
8. In a four−bar linkage, the sum of the lengths of the smallest and the longest link is
less than the sum of the lengths of the other two links. If the smallest link is
fixed, the linkage becomes a
(A) structure (B) double−rocker
(C) double crank mechanism (D) crank−rocker mechanism
9. For laminar flow though pipes, the friction factor is a function of

(A) Reynolds Number only and independent of roughness
(B) roughness only and independent of Reynolds Number
(C) both Reynolds Number and roughness
(D) neither roughness nor Reynolds Number
10. The ratio of compressor shaft power to the rate of energy transfer in a heat pump is
(A) C.O.P (B) 1/C.O.P. (C) η s (D) 1/ ηs
11. The shape of the particles of iron powder produced by electrolytic process is
(A) angular (B) acicular (C) spherical (D) dendritic
12. Thermosetting plastic among the following is

(A) nylon (B) teflon (C) PVC (D) bakelite
13. Given that the notations of robot joints are L−linear, O−orthogonal, R−rotational,
T−twisting, and V−revolving, the anatomy of a polar configuration robot is
described by the alphabetical string
(A) TOO (B) TLL (C) TRL (D) TVO
14. A job of the shape shown in Fig. below is to be machined on a lathe.
The tools best suited for machining of this job must have
(A) positive side rake angle (B) positive back rake angle
(C) positive cutting edge inclination angle (D) negative cutting edge inclination
angle
15. In which of the choices given below, the cutting tool materials are placed in the
ascending order of permissible cutting speed for machining of steel?
(A) K Group Cemented Carbide– P Group Cemented Carbide – Ceramic –
Cubic Boron Nitride
(B) Cubic Boron Nitride – K Group Cemented Carbide – P Group Cemented
Carbide – Ceramic
(C) P Group Cemented Carbide – K Group Cemented Carbide – Cubic Boron
Nitride – Ceramic
(D) Ceramic − Cubic Boron Nitride − K Group Cemented Carbide − P Group

Cemented Carbide
16. The cutting portion of a drill is to be welded to its shank. The process best suited
for this is
(A) ultrasonic welding (B) electron beam welding
(C) friction welding (D) laser welding
17. The shape factor for a casting in the form of an annular cylinder of outside
diameter 30cm, inside diameter 20cm and height 30cm (correction factor k = 1.0)
will be
(A) 3.80 (B) 6.28 (C) 9.42 (D) 12.28
18. The true stress−true strain curve is given by σ = 1400 ε 0.33 , where the stress σ is in
MPa. The true stress at maximum load (in MPa) is
(A) 971 (B) 750 (C) 698 (D) 350
19. The figure below shows the view through the eyepiece of Michelson’s optical
interferometer for testing the flatness and parallelism of slip gauges. The
interference bands indicate that the gauge is
(A) flat and parallel (B) flat, but the longer edges are not
parallel
(C) flat, but the shorter edges are not parallel (D) not flat
A cylindrical pin of diameter 1.996 +−00..0015

0015
20. mm is assembled into a hole of
+ 0.0015
diameter 2.000 − 0.0015 mm. The allowance (in mm) provided for this assembly is
(A) 0.001 (B) 0.015 (C) 0.025 (D) 0.035
21. The systematic study and collection of data on human body proportions is known
as
(A) Ergonomics (B) Physiology
(C) Biomechanics (D) Anthropometry
22. In the determination of standard time of an industrial process, which of the

following is covered under constant allowances?
(A) Basic fatigue (B) Monotony
(C) Tediousness (D) Mental strain
23. A linear programming problem has an unbounded solution when the replacement
ratio values are
(A) infinite or negative (B) infinite or positive
(C) finite or negative (D) finite or positive
24. For a stochastic decision making problem, the best alternative based on Expected
Monetary Value (EVM) and Expected Opportunity Loss (EOL) is obtained when?
(A) EVM is lowest possible or EOL is highest possible

(B) EVM is lowest possible or EOL is lowest possible
(C) EVM is highest possible or EOL is lowest possible
(D) EVM is highest possible or EOL is highest possible
25. A car costing Rs.3,00,000 is to be financed wholly by a bank loan at 10% interest
to be returned in 5 equal yearly installments. By which factor should Rs.3,00,000
be multiplied to get the annual installment to be paid?
(A) Compounding factor single payment

(B) Compounding factor for annuities
(C) Sinking fund deposit factor
(D) Capital recovery factor
26. The dominant problem in the design of process layouts is

(A) balancing the line
(B) providing efficient maintenance crew
(C) reducing the variety of parts
(D) minimizing the material handling effort
27. A company stocks five items having the following demand and cost data
Item Annual Demand (units) Cost / unit (Rs)
1 2000 40
2 3000 10
3 500 50
4 4000 15
5 1000 30
Using ABC classification, the top A class item is

(A) 4 (B) 3 (C) 2 (D) 1
28. If the hazard rate function of a critical equipment exhibits a typical “bath−tub”
curve, preventive maintenance is
(A) applicable during burn−in period
(B) applicable during useful life period
(C) applicable during wear−out period
(D) not warranted at all
29. Which of the following is a control chart by attributes?

(A) X chart (B) R chart (C) CUSUM chart (D) p−chart
30. For an activity in a project, the following data is available.

ES=6, EF=16, LS=33 and LF=43
The total float for this activity is
(A) 10 (B) 17 (C) 27 (D) 37
Q. 31 to Q. 80 carry two marks each
31. Laplace Transform of f(t) = cos (pt + q) is

s cos q − p sin q s cos q + p sin q
(A) (B)
s2 + p2 s2 + p2
s sin q − p cos q s sin q + p cos q

(C) (D)
s2 + p2 s2 + p2
32. Two dice are thrown simultaneously. The probability that the sum of numbers on
both exceeds 8 is
(A) 4/36 (B) 7/36 (C) 9/36 (D) 10/36
33. The life of a bulb (in hours) is a random variable with an exponential distribution
f (t) = αe −at , 0 ≤ t ≤ ∞ . The probability that its value lies between 100 and 200
hours is
(A) e −100 α − e −200 α (B) e −100 − e −200
(C) e −100 α + e −200 α (D) e −200 α − e −100 α
34. The surface φ (x, y, z) is given by 4 xz 2 − 3xy 2 + 3x = 5 . The unit vector at the
point (1, −2, 2) on the surface is given by

(A) 0.256i + 0.683j + 0.256k (B) 0.683i + 0.256j + 0.683k

(C) 0.863i + 0.256j + 0.863k (D) 0.863i + 0.683j + 0.863k
35. The temperature T (in  C ) at any point (x, y) on a surface is T = 400 xy2. The
highest temperature (in  C ) on the circumference of the circle x2 + y2 = 1 is

(A) 128 (B) 154 (C) 233 (D) 381
36. The eigen values of the matrix M given below are 15, 3 and 0.
 8 −6 2 
 
− 6 n − 4
 2 − 4 3 
The value of the determinant of the matrix is

(A) 20 (B) 10 (C) 0 (D) −10
37. The function w = u + iv = 1/2 log (x2 + y2) + i tan−1 (y/x) is NOT analytic and the
point
(A) 0, 0 (B) 0, 1 (C) 1, 0 (D) 2, 0
38. The real root of the equation x. ex = 2 is evaluated using Newton−Raphson’s

method. If the first approximation of the value of x is 0.8679, the second
approximation of the value of x correct to three decimal places is
(A) 0.865 (B) 0.853 (C) 0.849 (D) 0.838
39. In the frame shown below, each link is 300 mm long and the angle θ is 30  . To
retain the frame in equilibrium under the action of a force P of 120 N, the force F
(in N) required is
(A) 34.64 (B) 60.00 (C) 69.28 (D) 74.64
40. A ship is tied to a capstan with a rope passing over a guide roller. The friction
between the rope and the guide roller/capstan is 0.25. The angle of wrap on the
guide roller is 120  and that on the capstan is 1080  . If the shipside rope tension
F1 is 100 kN, the force F (in kN) needed to retain the ship in position at the
capstan is
(A) 0.532 (B) 2.53 (C) 5.85 (D) 59.2
41. A cantilever beam of cross section (bxh) 20x40 mm and of length 233 mm is
supporting a load of 1 kN at the free end. A simply beam made of same material
and having a cross section (bxh) 15x30 mm with identical load and deflection at
the centre will have a span of
(A) 100 (B) 220 (C) 400 (D) 530
42. A rectangular key of size 10 mm x 8 mm and length 40 mm is used to mount a

pulley on a shaft of 40 mm diameter. The key is equally sunk in both members.
The tensile yield strength of the key material is 240 MPa. If the permissible stress
in crushing is twice that in shear, the torque capacity (in Nm) of the joint for a
factor of safety 2, will be
(A) 284 (B) 384 (C) 480 (D) 580
43. The state of stress in a system is described by σ1 = 200 MPa, σ 2 = 90 MPa, and
σ 3 = 160 MPa. If a material of tensile yield strength of 400 MPa is used in the
system, the factors of safety by “Maximum shear stress theory” and “Maximum
distortion energy theory” respectively are
(A) 1.12, 1.25 (B) 1.23, 1.44 (C) 1.34, 1.57 (D) 1.54, 1.77
44. A pipe of 7 cm diameter with insulation of 3.5 cm thick asbestos (k = 0.17 W/m.
C) is exposed to room air at 25  c (with h = 3.0 W/m2.  C ). The inner
temperature of the pipe is 300  C . The heat transfer per unit length of the pipe (in
W/m) will be
(A) 153.86 (B) 195.48 (C) 220.23 (D) 348.99
45. In a fabrication shop, a T−joint is to be made between two plates using a chain
intermittent, double fillet weld of 6 mm leg length. The intermittent welds are 40
mm long and spaced 80 mm apart, edge to edge. The welding symbol of the joint
is
(A) (B)
(C) (D)
46. In a 10 mm diameter die cavity, metal powder is compacted to a height of 15 mm.

The die expansion is 10%. After ejection the spring back is 10%. During
subsequent sintering, the shrinkage is 10%. Final dimensions of the specimen
diameter and length (in mm) are
(A) 9, 14.85 (B) 10, 15 (C) 10.89, 14.85 (D) 11, 16.5
47. A flat surface S can be machined on a

cylindrical work piece located in a 90 
V−block in two ways
(i) either with reference to point P or
(ii) with reference to point Q as shown in
the figure below:
The ratio of the locating errors in the two cases (i): (ii) is
(A) 0.2929 : 1.7071 (B) 1.7071 : 0.2929
(C) 1.7071 : 0.7071 (D) 0.2929 : 0.7071
48. A φ 25 mm hole is pierced in a t = 2.5 mm thick steel sheet having shear strength
τ = 350 MPa. If the diametral clearance is given by the expression c = 0.0064 t
τ , the die diameter (in mm), punch diameter (in mm) and punch force (in kN)
respectively are
(A) 25.0, 25.3, 171.8 (B) 25.0, 24.7, 68.75
(C) 24.7, 25.0, 171.8 (D) 25.3, 25.0, 68.75
49. For machining the circular are shown

in the figure below on a NC machine,

interpolation parameters (I, K) and the
incremental movements in the directions
of X and Z axes are programmed as
(A) I = 0, K = R, X = − (R−P), Z = −Q (B) I = R, K = 0, X = − (R−P), Z = Q

(C) I = P, K = Q, X = R, Z = R−Q (D) I = Q, K = P, X = (R−P), Z = R
50. A non standard thread of pitch 3.175 mm is to be cut on a lathe having lead screw
pitch 6 mm. A change gear set provided with the lathe has one gear each with the
following number of teeth : 20, 30, 40, 50, 60, 70, 80, 90, 100,110, 120, 127. The
correct pairs of change gears (a/b × c/d) for machining the given thread are
(assuming that the transmission ratio of the rest of the kinematic train between the
lathe spindle and lead screw is equal to 1)
127 20 127 20 127 30 127 30
(A) × (B) × (C) × (D) ×
30 80 40 120 20 120 50 80
51. Two identical cylindrical jobs are turned using (a) a round nosed tool of nose
radius 2 mm and (b) a sharp corner tool having principal cutting edge angle =
45  and auxiliary cutting edge angle = 10  . If the operation is carried out at a

feed of 0.08 mm/rev, the heights of micro irregularities on the machined surfaces
(in mm) in the two cases will be
(A) 0.0001, 0.024 (B) 0.0002, 0.012
(C) 0.0003, 0.024 (D) 0.0004, 0.012
52. A φ 20 mm through hole is to be drilled in a 30 mm thick plate using a double
fluted, 120  lip angle drill. The drill tip is at a distance of 3mm from the plate
surface when cutting is started and an over travel of 2 mm is recommended as a
margin to ensure drilling through the full thickness of the plate. If the drill rotates
at 500 rev/min and the feed per tooth is 0.01 mm, the machining time of the
operation (in sec) will be
(A) 48.92 (B) 19.80 (C) 24.46 (D) 21.00
53. A lathe produces cylindrical jobs with a standard deviation σ = 0.013 mm. For
machining a job of diameter 30 +−00..10

00
mm, the Process Capability Index of this
machine is
(A) 1.28 (B) 1.64 (C) 1.92 (D) 2.56
54. Two 8 mm thick steel plates are placed 5 mm apart and welded by a butt joint.
Welding is carried out at 20 V and speed of 5 mm/sec. Heat transfer efficiency is
0.80. If the heat required to melt steel is 10 J/mm3 and melting efficiency is
0.625, the weld current (in Amperes) will be
(A) 100 (B) 200 (C) 300 (D) 400
55. A cast steel slab of dimension 30x20x5 cm is poured horizontally using a side
riser. The riser is cylindrical in shape with diameter and height, both equal to D.
The freezing ratio of the mould is
(A) 8D / 75 (B) 4D / 75 (C) 75 / 8D (D) 75 / 4D
56. A round billet made of brass is to be extruded (extrusion constant = 250 M Pa) at
700  C . The billet diameter is 100 mm and the diameter of the extrusion is 50
mm. The extrusion force required (in MN) is
(A) 1.932 (B) 2.722 (C) 3.423 (D) 4.650
57. An ISO metric thread has a pitch error of 0.2 mm over its length of engagement.
The virtual change in effective diameter (in mm) is
(A) 0.057 (B) 0.100 (C) 0.173 (D) 0.346
58. Three components of equal tolerances are assembled to build up a length for
which the maximum permissible variation is 0.27 mm. If statistical concepts of
tolerance build up are used to replace the normal algebraic considerations, the
permissible increase in tolerance (in %) is
(A) 68.5 (B) 70.2 (C) 73.3 (D) 80
59. A project has an estimated cost of Rs. 10 Lakhs and is likely to yield a net profit
(in Lakhs of Rs) of 2, 3, 5,5 at the end of the next four successive years. If the
interest rate is 8%, the net present value (in lakhs of Rs) for the 4 year horizon is
(A) 12.068 (B) 10 (C) 5 (D) 2.068
60. A machine costs Rs. 5,00,000. The life of the machine is 5 years and the terminal
salvage value is zero. The depreciation of the machine is based on the sum of
digits principle. Assuming undiscounted cash flows, the book value (in Rs) of the
machine after 2 years is
(A) 400,000 (B) 300,000 (C) 200,000 (D) 100,000
61. A manager must assign three engineers to three different tasks. Estimates of the
time (in hours) to complete each task for every engineer are given below
Time to complete
Engineer
Task 1 Task 2 Task 3
P 10 12 16
Q 12 24 20
R 14 20 24
The total time (in hrs) for the best assignment and the engineer who completes his
work the last are
(A) 36, P (B) 46, Q (C) 46, R (D) 48, R
62. The precedence diagram of 10 elements to be included in the design of an

assembly line is given below. The times (in minutes) to perform these elements
are indicated adjacent to each element
The minimum cycle time (in minutes) possible and the theoretically minimum
number of work stations for the assembly line are respectively
(A) 2, 5 (B) 8, 5 (C) 8, 6 (D) 43, 6
63. A chemical plant can be set up in Mumbai with fixed costs of assets at Rs 30 Lakhs
and annual operating costs of Rs 5 lakhs / ton of output.
Alternatively, it can be set up in Gurgaon with fixed cost of Rs 20 lakhs and annual
operating costs of Rs 10 lakhs / ton. The breakeven plant capacity and the
preferred site for operation at double the breakeven capacity are
(A) 2 tons, Gurgaon (B) 2 tons, Mumbai
(C) 30 tons, Gurgaon (D) 20 tons, Mumbai
64. Six manuscripts lying with a publisher have the following printing and binding
times
Manuscript Printing Time Binding Time
(weeks) (weeks)
Manuscript
1 2 1
2 3 2
3 5 1
4 1 3
5 4 2
6 2 1
Determine the sequence in which these manuscripts be scheduled for printing and
binding to minimize the makespan. The minimum makespan (in weeks) is
(A) 15 (B) 16 (C) 17 (D) 18
65. The reliability of an equipment for a time to failure exceeding t hours is given by
R(t) = exp (−0.002t). The mean time to failure (MTTF) for this equipment (in
hrs) is
(A) 300 (B) 400 (C) 500 (D) 600
66. Components are supplied to a factory with average fraction defective of 0.01. The
factory quality control manager uses a single sampling plan for inspection with a
sample size of 10 and an acceptance number of zero. What is the consumer’s risk
if the lot tolerance percentage defective is 2%?
(A) 0.99 (B) 0.904 (C) 0.871 (D) 0.817
67. A newly designed product has annual fixed costs of Rs 4 lakhs, unit variable cost
of Rs 500/piece and an anticipated selling price of Rs 700/piece. The range of
demands for a profit realization between Rs 2−3 lakhs/annum is
(A) (1000−2000) (B) (2000−2500)
(C) (3000−3500) (D) (4000−5000)
68. An analyst wishes to determine the idle time of the workers in a shop having 5
workers. An initial study indicated that out of 10 observations, only on one
occasion one worker was idle. The analyst wishes a more accurate study to
estimate the idle time within ± 1 percent of true value, with a 95 percent
confidence. The number of trips required is
(A) 620 (B) 720 (C) 900 (D) 3600
69. The observed time is recorded to be 20 minutes for a job done by a worker whose
rating is 90. The following allowances are recommended by the management:
i Personal needs allowance: 4% of basic time

ii Basic fatigue allowance: 1% of basic time
iii Contingency work allowance: 2% of basic time
iv Contingency delay allowance: 3% of basic time
The work content of the job is

(A) 18 min (B) 19 min 15.6 sec
(C) 19 min 26.4 sec (D) 19 min 48 sec
70. A company is evaluating two investment policies whose returns are based on the
state of economy. The possible states of economy along with associated
probability distributions and returns are given below:
State of economy Fair Good Great
State of
economy
Probability 0.3 0.5 0.2
Return on Policy 1 −4000 6000 8500
Return on Policy 2 −10000 8000 10000
By how much is the expected return (in Rs.) in policy 1 better than in policy 2?
(A) 1500 (B) 1300 (C) 1000 (D) 500
71. A work center has three drills operated by three operators working eight hours a
day, five days a week. Records indicate that machine utilization is 95% and
operator efficiency is 85%. What is the effective work center capacity (in hours)
per day?
(A) 19.38 (B) 20.40 (C) 22.80 (D) 96.90
72. In the decision table given below, the two decision rules contributing to
redundancy are
Rule 1 Rule 2 Rule 3 Rule 4

Condition 1 T T F T
Condition 2 F F T T
Condition 3 F T
Action 1 X X
Action 2 X
Action 3 X
(A) Rule 1 & Rule 2 (B) Rule 1 & Rule 3

(C) Rule 2 & Rule 3 (D) Rule 3 & Rule 4
Q. 73 to 78 are “Matching” exercises. Choose the correct one out of the alternatives A,
B, C, D
73.
.Alloying elements of Cast Iron Properties Imparted
P. Silicon 1. Decreases fluidity
Q. Sulphur 2. Promotes graphitization
R. Manganese 3. Lowers melting point
S. Phosphorus 4. Promotes resistance to
graphitization
(A) P−2, Q−4, R−1, S−3 (B) P−2, Q−1, R−4, S−3
(C) P−3, Q−4, R−1, S−2 (D) P−1, Q−3, R−2, S−4
74.
Alloys Based on Applications
P. Magnesium 1. I.C. Engine Pistons
Q. Copper 2. X−Ray shields
R. Aluminium 3. High Speed rotating elements in
textile machinery
S. Lead 4. Heat Exchangers
(A) P−4, Q−3, R−1, S−2 (B) P−1, Q−4, R−3, S−2
(C) P−3, Q−4, R−1, S−2 (D) P−3, Q−1, R−2, S−4
75.
Desired aspects Strategies
P. Demand 1. Concurrent Engineering
Q. Time to market 2. Ergonomics

R. Variety reduction 3. Value Engineering
S. Quality/cost ratio 4. Market research
T. Man−machine interface 5. Standardization
(A) P−3, Q−2, R−1, S−5, T−4 (B) P−2, Q−4, R−1, S−5, T−3
(C) P−1, Q−4, R−2, S−5, T−2 (D) P−4, Q−1, R−5, S−3, T−2
76.
Automation Strategy Type of

equipment
P. Standalone programmable manufacturing 1. Transfer line
automation
Q. Programmable automation with automatic 2. CNC
tool changing
R. Dedicated automation with automated 3. FMS
material transfer
S. Programmable automation with programmable 4.Machining
material handling and transfer center
(A) P−2, Q−3, R−4, S−1 (B) P−4, Q−2, R−3, S−1
(C) P−1, Q−2, R−3, S−4 (D) P−2, Q−4, R−1, S−3
77.
Mechanism of Material Removal Process

P. Abrasive grain throwing and 1. ECM
hammering
Q. Erosion due to vaporization 2. USM
R. Chipping and erosion 3. PAM
S. Melting and partial vaporization 4. EDM
T. Electrolysis 5. AJM
(A) P−3, Q−2, R−5, S−1, T−4 (B) P−4, Q−3, R−2, S−1, T−5
(C) P−2, Q−4, R−5, S−3, T−1 (D) P−2, Q−5, R−3, S−1, T−4
78.
Group 1 Group 2
P. Tardiness 1. Johnson’s Rule
Q. Makespan 2. Negative lateness
R. N/M Job Shop Scheduling 3. SPT
S. WIP 4. Positive lateness
5. NP Complete
(A) P−4, Q−1, R−3, S−5 (B) P−4, Q−1, R−5, S−3
(C) P−2, Q−3, R−5, S−1 (D) P−2, Q−1, R−3, S−5
Common Data Questions
Common Data for Questions 79, 80
A manufacturer makes two animal feeds P and Q and employs three workers W1, W2 and
W3. The time taken by workers (in hours) to produce on kg of each feed and the times
for which each worker is available are given below:
Worker Item P Item Q Time Available
W1 4 3 12
W2 − 1 3
W3 5 3 15
The contributions of P and Q (per kg) to profit are Rs. 100 and Rs. 150 respectively.
79. Currently the operations include only W1 and W2 as indicated in the figure
below:
If the production of P, Q is (0, 3), the idle times of W1 and W2 respectively are
(A) (3, 0) (B) (0,3) (C) (3, 3) (D) (1, 1)
80. Suddenly W1 leaves and the operations are run by W2 and W3 only. The
maximum profit (in Rs) now is
(A) 300 (B) 550 (C) 570 (D) 590
Linked Answer Questions: Q.81a to Q.85b carry two marks each

Statement for Linked Answer Questions 81a & 81b
A welded double lap joint of 70 mm width and 10 mm fillet size is shown in the figure below.
81a. If the permissible shear stress for the weld material is 60 MPa and the effect of
normal stress is neglected, the load carrying capacity (in kN) of the welded joint is
(A) 16.56 (B) 29.69 (C) 42.93 (D) 85.87
81b. If the welded joint is replaced by a riveted joint with four identical rivets of shear
strength 48 MPa and crushing strength 96 MPa, the minimum size of the rivet
needed to sustain the same load is
(A) 10 (B) 12 (C) 16 (D) 20

Water at 20  C (ρ = 1000 kg / m 3 ) flows at the rate of 10 kg/s through a diffuser (circular
cross sectional area) from section1 to 2. The diameters at sections 1 and 2 are 4.0 and 8.0
cm respectively. Assume the flow to be frictionless.
82a. The velocities (in m/s) at sections 1 and 2 will respectively be

(A) 7.962 and 1.989 (B) 8.529 and 2.038
(C) 9.069 and 3.848 (D) 3.848 and 0.269
82b. The increase in static pressure (in kPa) between sections 1 and 2 will be
(A) 14.83 (B) 29.72 (C) 31.83 (D) 44.69

The demand of a product for the last 3 months is indicated below
January 460
February 511
March 520
83a. Using the average of these values as a starting forecast for April, exponential
smoothing is to be initiated for future forecasting. If the actual demand for April
is 527, forecast for May is (smoothing constant, α = 0.1)
(A) 480 (B) 497 (C) 500 (D) 527
83b. The product above is to be ordered from a supplier. The ordering cost is Rs.100
and the carrying cost rate is 10%. The item cost is Rs.200. Based on the forecast
of demand for May, the optimal order quantity is
(A) 39 (B) 50 (C) 71 (D) 96
Statement for Linked Answer Questions 84a & 84b:

A batch of 500 jobs of diameter 50 mm ad length 100 mm is to be turned at 200 rev/min
and feed 0.2 mm/rev.
84a. Applying Taylor’s equation VT 0.25 = 160, the tool life in minutes is
(A) 20.36 (B) 22.43 (C) 24.51 (D) 28.20
84b. The number of tool changes required to machine the whole batch is
(A) 138 (B) 86 (C) 62 (D) 61
Statement for Linked Answer Questions 85a & 85b :

A φ 40 mm job is subjected to orthogonal turning by a + 10  rake angle tool at 500
rev/min. By direct measurement during the cutting operation, the shear angle was found
equal to 25  .
85a. The velocity (in m/s) with which the chip flows on the tool face is
(A) 32 (B) 26 (C) 22 (D) 18
85b. If the friction angle at the tool−chip interface is 58  10 ′ and the cutting force
components measured by a dynamometer are 600 N and 200 N, the power loss
due to friction (in kNm/min) is approximately
(A) 20 (B) 18 (C) 16 (D) 14
******************
SOLUTIONS
PI − 2005
1. (D)
Stokes theorem gives relation between surface integral & line integral. Gauss
divergence theorem volume integral & line integral. Greens theorem gives line
integral.
2. (B)
Newton Raphson gives the relation
f (x n )
x n +1 = x n −
f ′(x n )
3. (C)
3 2
  dy  2   d2y 
1 +    = c 2  
  dx    d2x 
2nd order derivative & its degree = 2
4. (A)
f (x n )
x n +1 = x n −
f ′(x n )
5. (B) 6. (D) 7. (C)
9. (C)
The following given equation is known as Darcy-Weisbach equation used to
calculate pressure head loss due to friction.
fLV 2
hf =
2gD
where h f = pressure head loss due to friction.

f = friction factor
L = length of pipe
D = Diameter of pipe
V = fluid velocity
The friction factor f is not a constant but its value depends on roughness condition
of the pipe surface and Reynolds number of the flow.
10. (B) 11. (D) 12. (D)
13. (C) 14. (D)
15. (A)
Cutting speed in ascending order for different cutting tool materials is as follows:
carbon steel, HSS, sintered carbides, coated HSS, ceramics, polycrystalline CBN
and Diamond. Within three ISO grades of carbides, the cutting speed in the
ascending order is − K Group, M Group and P Group.
16. (C)
17. (D)
Naval Research Lab (NRL) method of determining casting riser size is essentially
a simplification of Caine’s method. It defines a shape factor to replace freezing
ratio used in Caine’s method. The shape factor is defined as
Length + width
=
Thickness
The length, width and thickness are computed from the maximum dimensions of
the casting section. Then the ratio of riser volume to casting volume is obtained
from graph. From riser volume, dimensions of riser can be found. It has been
proven empirically that for side risers the height to diameter ratio be 1 and for top
riser it be 0.5.
For circular plates, the length and width are same as that of diameter. But for
cylinders, the width and the thickness are same as the diameter for calculating
shape factor. For hollow cylindrical shapes, a correction factor (k) is applied to
get effective plate thickness. If ‘T’ is true wall thickness, then correction factor is
given by
core dia. 0.5 T T 2T 4T
correction factor k 1.17 1.14 1.02 1.00
30 − 20
T = wall thickness = = 5 cm
2
dc = core dia = 20 cm = 4T
k = correction factor = 1.00 (given)
L + W 30 + 30
Shape factor = = = 12
kT 5
18. (A)
Hollomon equation σ = Kε n defines stress strain curve. For a given material,
σ = 1400 (ε) 0.33 . At maximum load, true strain ε is equal to strain hardening
exponent n. Hence ε = n .
σ = 1400 (0.33) 0.33 = 971MPa
19. (A)
20. (A)
Allowance is a dimensional difference between the maximum material limits of
mating parts, intentionally provided to obtain desired class of fit. If the allowance
is positive, it will result in minimum clearance between the mating parts and if
allowance is negative, it will result in maximum interference.
Allowance = min. hole size − max. pin size
Personal = 1.9985 − 1.9975 = 0.001 mm.
Needs
Fixed
21. (D)Basic Allowance
fatigue Relaxation Total
Allowance Allowances
22. (A)
Environment
Basic Model for Allowances:
+
Variable Contingency
Stress, strain
Allowance Allowance Basic
Time
Policy
Allowance
Work
content
Special
Allowance
Basic Model for Allowances

23. (A)
Identifying special cases from simplex table:
(i) If the constraint coefficient of entering variable in the simplex table are either
less than or equal to zero, then solution space is unbounded and has no finite
optimum solution.
(ii) When there are no non-negative replacement ratios (so that all of them are
negative) or they are equal to (for the reason of the denominator equal to zero)
then an LPP is said to have an unbounded solution.
25. (C) 26. (D) 27. (D)
28. (B) 29. (D) 30. (A)
31. (A)
L (cos (pt + q)) = L (cos pt + cos q − sin pt sin q)
= cos q L (cos pt) − sin q L (sin pt)
s p
= cos q 2 − sin q
s + p2 s2 + p2
s cos q − p sin q
∴
s2 + p2
32. (D)
Two dice are thrown
n (s) = 36
A: sum exceeds 8
⇒ sum 9, 10, 11, 12
n (A) (3, 6) (4, 5) (4, 6) (5, 4) (5, 5) (5, 6) (6, 3) (6, 4) (6, 5) (6, 6)
n(A) 10
P(A) = =
n(s) 36
33. (A)
200 200
− at
 e −at 
∫ ae = a 
 −a 100
100
= −e −200t + e −100t
34. ∇φ = (4z 2 − 3y 2 + 3)i − (6xy) j + 8xzk

(∇φ) (1, −2, 2) = (16 − 12 + 3) i + 12 j + 16 k
= 7i + 12j + 16k
| ∇φ | (1, −2, 2) = 7 2 + 12 2 + 16 2
= 49 + 144 + 256
= 449 = 21.19
(∇φ) (1, −2, 2)
Unit vector =
| ∇φ |(1, −2, 2)
7 12 16
= i+ j+ k
21.19 21.19 21.19
= 0.330 i + 0.566 j + 0.7550 k
Ans not properly given.
35. (C)
400 ∫ x 1 − x 2 dx
= 400 ∫ x(1 − x 2 )1/ 2
= −200∫ −2x(1 − x 2 )1/ 2
1
 2 3/ 2 
= −200  (1 − x ) 
 3/ 2 0
400 400
=− (0 − 1) = = 133
3 3
36. (C)
Sum of eigen values = sum of diagonal elements
8 + n + 3 = 15 + 3 = 0
11 + n = 18
n=7
det = | A | = product of eigen values if matrix is non singular.
But one of the eigen values is zero ⇒ matrix M is singular
∴ |A|=0
Verify: 8 [21 − 16] + 6 (−18 + 8) + 2 (24 − 14)
= 8 (5) − 60 + 20 = 0
37. (A)
1
W = u + iv = log(x 2 + y 2 ) + i tan −1 y / x
2
f(z) = u + iv
1
u= log(x 2 + y 2 ) v = tan −1 y / x
2
x y
ux = , uy =
2 2
x +y x + y2
2
 x 2   −1  1
vx =   =−
 x 2 + y 2   x 2  x + y2
2
 
x2 1 x
vy =  = 2
x + y  x  x + y2
2 2
Function is differentiable except at (0, 0)
38. (B)
f (x) = xe x − 2 = 0
f ′(x) = xe x + e x
f (x n )
x n +1 = x n −
f ′(x n )
f (x 0 )
n = 0, x1 = x 0 −
f ′(x 0 )
0.067254
x1 = 0.8679 −
4.44915
= 0.8679 − 0.0151
= 0.8528 = 0.853
41. (C)
∆ = deflection in both cases is being equal
PL31 PL32
∆= =
3EI1 48EI 2
where E = Elasticity modulus is same for same material
bd 3 20 × 403
I1 = =
12 12
15 × 303
I2 =
12
3 3
∴  L2  I2 15  30 
 L  = 16 × I = 16 × 20 ×  40  = 5.0625
 1 1
L2
∴ = 1.717 ∴ L 2 = 400 mm
L1
PL31 PL32
∆= ∆=
3EI1 48EI 2
42. (C)
P = tangential force
d = shaft diameter
M = transmitted torque
P
τ = shear stress =
b× L
According to the maximum shear stress theory,

1
yield strength of material in shear = × (yield strength of material in tension)
2
1
= × 240 = 120 N / mm 2
2
since factor of safety is given 2,
1
τa = allowable shear stress = × 120 = 60 N / mm 2
2
P = τa × b × L = 60 ×10 × 40 N = 24 kN
d 40
M = P× = 24 × = 480 kN.mm
2 2
M = 480 N.m
(ii) The failure due to compressive stress would occur on AC and B

P 2P
σc = =
∴ h h×L
×L
2
crushing strength = 2 × shear strength = 2 × 120 = 240 N/ mm 2
1
Allowable crushing strength with safety factor 2 = × 240 = 120 N / mm 2
2
2P
∴ 240 = ∴ P = 38.4 kN
8 × 40
d 40
M = P× = 38.4 × = 768 kN.mm
2 20
M = 768 N.m
The limiting torque in this case arises from shear strength and is 480 N.m
43. (D)
Arranging the principal stresses in descending order and redesignating,
σ1 = 200 MPa, σ 2 = 160 MPa, σ3 = 90 MPa
(i) Tresca criterion:

σ = effective stress ( Tmax in this case)
= σ1 − σ3 = 200 − 90 = 110 MPa

σ 0 tensile yield strength of material
Factor of safety = =
σ σ
400
= = 3.636
110
(ii) Von Mises criterion:
σ = effective stresses
1
σ= [(σ1 − σ 2 ) 2 + (σ 2 − σ3 ) 2 + (σ3 − σ1 ) 2 ]1/ 2
2
1
= [(200 − 160) 2 + (160 − 90) 2 + (90 − 200) 2 ]1/ 2
2
1
= (40 2 + 70 2 + 110 2 )1/ 2 = 96.43
2
σ0 400
Factor of safety = = = 4.14
σ 96.43
Note: All alternative answers provided are not correct
44. H = Heat transfer rate from pipe to atmosphere

2πL(T1 − Ta )
 r 
=  log 2 
1 r1
 + 
 h ⋅ r2 k 
T1 = Inner temp. of pipe = 300°C
Ta = atmosphere temp = 25°C
h = coeff. of emissivity = 0.3 W/ m 2

k = Insulation conductivity = 0.17 W/m °C
L = length of pipe = 1 m
r1 = radius of pipe = 7/2 cm = 3.5 cm
r2 = radius of insulation = 3.5 + 3.5 = 7 cm = 0.07 m
2π(300 − 25) 1727.8

H= = = 195.48 W / m
7 (4.76 + 4.077)
log
1 3.5
+
3 × 0.07 0.17
45. (A)
46. (C)
(i) On compaction, diameter of compact will be 11 mm (10% more due to die
expansion), but height will be 15 mm only.
(ii) Due to spring back ejection, the diameter and height will further increase by
10% i.e. 12.1 mm and 16.5 mm respectively.
(iii) The shrinkage will be throughout the volume and both height and diameter
will shrink by 10% i.e. diameter will reduce to 10.89 mm and height to 14.85
(i) (ii) (iii)
48. (D)
d = diameter of punched hole = 25 mm

= diameter of punch
∴ punch diameter = d p = 25.00 mm
die bore diameter d b = d p + diametral clearance

t = stock thickness = 2.5 mm
T = shear strength = 350 N/ mm 2
∴ c = diametral clearance = 0.0064t × τ
= 0.0064 × 2.5 × 350 = 0.3 mm

∴ die bore (diameter) = 25.00 + 0.3 = 25.3 mm
(ii) Punch force = cutting diameter × t × τ

= (π× 25) × 2.5 × 350 N
= 68.72 kN
50. (B)
The ratio of driving wheel (wheel on spindle) to the driven wheel (wheel on lead
screw) is given
Driver teeth pitch of the work
=
Driven teeth pitch of the lead screw
3.175 3.175 1
= = × 40 ×
6 3 2
3.175 × 40 20
= ×
3 × 40 40
as the minimum number of teeth on a gear can be 20 and maximum 120
127 20 127 20
= × = ×
120 40 40 120
51. (D)
f2
(a) the height of micro irregularities on the machined surfaces =
8R
f = feed mm/rev = 0.08 mm/rev
R = nose radius = 2
f 2 (0.08) 2
h= = = 0.0004 mm
8R 8 × (2)
(b) For a sharp corner tool having principal cutting edge angle 45° and auxiliary
cutting edge angle = 10°
f
h=
tan ζ s + cot ζ e
ζ s = side cutting edge angle = 45°
ζ e = auxiliary or end cutting edge angle = 10°
0.08 0.08
h= = = 0.012 mm
tan 45° + cot10° 1 + 5.671
52. (C)
D
A=
2 × tan β
D = Drill diameter = 20 mm
2β = drill point angle = 118°
20
∴ A= = 6 mm
2 tan 59°
Total drill travel = plate thickness + Approach distance + Break through clearance
= 30 + 3 + 6 + 2 = 41 mm
feed per revolution f = 2 × feed per tooth = 2 × 0.1 = 0.2
L 41
Machining time T = = min = 24.6s
f × N 0.2 × 500
53. (A)
The process capability Index
tolerencespeed
=
6σ
0.00 − ( −0.1) 0.1
= = = 1.28
6 × 0.013 6 × 0.013
54. (B)
Volume of metal melt per sec = thickness of plate × gap × welding speed
= 8 × 5 × 5 = 200 mm3 /s
∴ Heat required per sec = 200 × 10 = 2000 J/s
Out of 100 units, only 80 units are transferred to joint and out of transferred heat
only 62.5% is used for melting.
∴ Heat supplied = V × I × 0.8 × 0.625
As Heat supplied = Heat required
⇒ VI × 0.8 × 0.625 = 2000
and V = 20 V
20 × I × 0.8 × 0.625 = 2000
I = 200 Amp
55. (A)
(A / V) C
Freezing ratio =
(A / V) R
A = cooling surface area
V = volume
C = subscript for casting
R = subscript for Riser
2(20 × 30 + 30 × 5 + 20 × 5)
(A / V) C =
20 × 30 × 5
600 + 150 + 100 850 85
= = =
1500 1500 150
π 2
D + πD × D
4 5
(A / V) R = =
π 2 D
D ×D
4
85 D 17D 8D
X= × = ≈
150 5 150 75
56. (B)
A0
F = A 0 k ⋅ log e
A1
π
where A 0 = billet cross section = (100) 2
4
π 2 π
A1 = extrusion cross section = d1 = (50) 2
4 4
k = extrusion constant = 250 MPa = 250 N/ mm 2
2
A 0  100 
=  =4
A1  50 
π
F = 250 × (100) 2 × log e 4 N
4
= 2722 kN = 2.722 MN
57. (D)
59. (D)
 C C2 C3 C4 
NPV =  1 + + + − C0
(1 + r) 2 3 4
 (1 + r) (1 + r) (1 + r) 
 2 3 5 5 
= + + + − 10 = 2.068 Lakh
(1.08) 2 3 4
 (1.08) (1.08) (1.08) 
60. (C)
n(n + 1) 5 × 6
Sum of digits of years = = = 15
2 2
where n = life of machine
The rate of depreciation charge for the first year is assumed to be highest and then
it decreases. The rate of depreciation per year 1 to 5 respectively as
5/15, 4/15, 3/15, 2/15 and 1/15
Depreciation = Depreciation rate × (First cost of asset − salvage value)
Year Depreciation Book value

Rs. (in Lakh) Rs. (in lakh)
0 5
1 5 5 5 10
5× = 5− =
15 3 3 3
2 4 4 10 4
5× = − =2
15 3 3 3
61. (B)
Solve the problem by assignment method. Allocation is as follows:
Engineer Task Time to complete
P Task 2 12
Q Task 3 20
R Task 1 14
Hence total time for best assignment is 46 hours and engineer Q completes his
work last, 20 hours.
62. (C)
63. (B)
The total cost equation applicable will be
Fixed cost + volume × operating cost rate
For Mumbai, 30 + 5 × Q
For Gurgaon, 20 + 10 × Q
At breakeven, 30 + 5Q = 20 + 10 × Q
Q = 2 ton
∴ Breakeven output is 2. Preferred site for operation at double the breakeven
capacity is Mumbai as total cost of operation will be lesser than that of Gurgaon.
64. (D)
Order of sequencing of loading job is
4 5 2 3 1 6
The minimum makespan is computed as follows:
Manuscript Printing Binding

In Out In Out
4 0 1 1 4
5 1 5 5 7
2 5 8 8 10
3 8 13 13 14
1 13 15 15 16
6 15 17 17 18
Hence minimum makespan is 18 weeks.
65. (C)
Reliability of a unit R(t) = e −λt
λ = failure rate
t = mission time
m = mean time between failure (MTBF) is time between two consecutive failures
1
=
λ
Give R(t) = e −0.002 t

∴ λ = 0.002
1 1
MTBF = = = 500 hours
λ 0.002
67. (C)
F = fixed cost, π = profit, P = price, V = variable cost
F + π = Q(P − V)
where Q = volume of production (which is subsequently sold)
The value of demand and range (Q) works between 3000 to 3500 units realize
profit between Rs. 2 to 3 lakh.
68. (D)
pq
σp =
n
σ p = standard error in proportion
p = percent of idle time = 10%

q = percent of working time = 90%
n = number of observations or sample size we wish to determine
At a confidence level of 95% with 1% margin of error i.e. we are confident that in
95% of our estimate will be ±1% of real value.
∴ 1.96 σ p = 1
σ p = 0.5
pq
σp =
n
10 × 90
0.5 = ∴ n = 3600
n
69. (D)
rating
Basic time = × observed Time
Standard Rating
90
= × 20 = 18 min
100
Work content = Basic time + Allowance
Total allowance = 10% of basic time
= 0.1 × 18 = 1.8 min
∴ Work content = 18 + 1.8 = 19.8 min = 19 min 48 sec
71. (A)
Total work center capacity = 8 × 3 = 24 hours per day
Machine availability = 0.95 × 24 hours = 22.8 hours

Out of 22.8 hours per day, workers are able to use it 85% of time as worker
efficiency is 85%.
∴ effective work capacity = 0.85 × 22.8 = 19.38 hours/day
73. (A)
Silicon is a strong graphitizer and promotes graphitization. Most of the
phosphorus combines with iron and forms iron phosphide (Fe3P) . This iron
phosphide separates as eutectic (low melting point) mixture with cementite and
austentite. Sulphur combines with iron and forms iron sulphide which is hard and
brittle compound. Further, sulphur in the form of FeS promotes formation of iron
carbide without participating in its formation. It has strong effect as carbide
stabilizer and 0.01% sulphur is sufficient to neutralize the graphitizing influence
of 0.15% silicon and hence resists the formation of graphite.
74. (C) 75. (D) 76. (D)
77. (C) 78. (D) 79. (A)
80. (C)
81a. (B)
Transverse fillet weld subjected to load 2F.
2F
Tensile stress intensity induced in the weld =
2 × L × h × sin 45°
2F
60 =
2 × 70 ×10 × sin 45°
F = 29698 N = 29.69 kN
81b. (C)
2F 29.69
Load per rivet = = = 14.845 kN
4 2
π 2 
shear strength of rivet four double shear = 2 ×  d × shear stress 
4 
π
∴ 2 × d 2 × 48 = 14845 N
4
d = 14.03 mm
d = 16 mm
82a. (A)
m 10
Volume flowing rate, V = =
ρ 1000
1 3
= m / s = 10 4 cm 3 / s
100
A1 × V1 = A 2 × V2
π 2
∴ d1 × V1 = 10 4 cm 3 d1 = 4 cm
4
∴ V1 = 796 cm / s
∴ V1 = 7.96 m/s
V2 = 1.989 m/s
82b. (B)
Using Bernoulli’s equation
P V2
+ = constant
ω 2g
where ω = specific weight = density × g
= 1 × 9.81 = 9.81 N for water
P1 V12 P2 V22
∴ + = +
ω 2g ω 2g
(P2 − P1 ) V12 − V22

∴ =
ω 2g
V 2 − V22 V 2 − V22
(P2 − P1 ) = 1 ×g = 1
2g 2
7.96 2 − 1.989 2
= = 29.72
2
83a. (C)
460 + 511 + 520
Average of three months = = 497
3
Forecast for April = 497
Actual for April = 527
Using exponential smoothening, forecast for the month May
= Av. forecast for the last period + α [Actual demand for the last period
− Av. forecast for the last period]
= 497 + 0.1 [527 − 497]
= 500
83b. (C)
R = Demand for month May = 500
C1 = Inventory carrying cost = 0.1 × 200 = Rs. 20
C3 = ordering cost = Rs. 100
2C3R
q 0 = optimum order quantity =
C1
2 ×100 × 500
=
20
= 70.7 = 71 units
84a. (A)
D = turning diameter = 50 mm
L = length of turning = 100 mm
N = RPM = 200 rev/min
f = 0.2 mm/rev
πDN π× 50 × 200
V= m / min = = 31.41 m/min
1000 1000
The given alternatives are not correct with given Taylor equation VT 0.25 = 160
Selecting proper
VT 0.25 = 67
T = 20.26 min
84b. (C)
The number of total changes required:
L 100
Machining time for each job = = = 2.5 min
f × N 0.2 × 200
Total machining time = 500 × 2.5 = 1250 min
1250 1250
n = tool changes = = = 62
Tool life 20.26
85a. D = Diameter of job = 40 mm

ζ = rake angle = 10°
N = 500 rpm
φ = shear angle = 25°
πDN π× 40 × 500
V = cutting velocity = = = 20π
1000 1000
= 62.83 m/min
Vc = velocity of chip
Vs = shearing velocity
V = cutting velocity
Using sine law,

Vc V
− =
sin φ sin[90 − (φ − ζ )]
sin φ
Vc = V ×
sin[90 − (φ − ζ )]
sin 25°
= 62.83 × = 27.5 m/min
sin[90 − (25 − 10)]
The correct answer is 27.5 m/min
85b. FC = 600 N
FT = 200 N
F = Frictional force
N = Normal force
F = FC sin ζ + FT cos ζ
= 600 sin 10° + 200 cos 10°

= 301.15 N
VC = chip velocity
Merchant circle
Power loss per min = F × VC

= 301.15 × 27.5 N.m/min = 8.28 kN.m/min ≈ 9 kN.m/min

The correct answer is 9 kN.m/min.
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GA/QB/PI−IV Elite Academy 25

Duration: Three hours Maximum Marks : 150

Read the following instructions carefully

Q.1 – Q.30 carry one mark each

1. Which one of the following is NOT associated with vector calculus?

4. Newton-Raphson formula to find the roots of an equation f(x) = 0 is given by

(C) µ > cos α . tanλ (D) µ < cos α. tan λ

(A) 100 (B) 173 (C) 200 (D) 273

9. For laminar flow though pipes, the friction factor is a function of

(A) angular (B) acicular (C) spherical (D) dendritic

12. Thermosetting plastic among the following is

14. A job of the shape shown in Fig. below is to be machined on a lathe.

(D) Ceramic − Cubic Boron Nitride − K Group Cemented Carbide − P Group

A cylindrical pin of diameter 1.996 +−00..0015

(A) 0.001 (B) 0.015 (C) 0.025 (D) 0.035

22. In the determination of standard time of an industrial process, which of the

(A) EVM is lowest possible or EOL is highest possible

(A) Compounding factor single payment

26. The dominant problem in the design of process layouts is

Using ABC classification, the top A class item is

29. Which of the following is a control chart by attributes?

30. For an activity in a project, the following data is available.

31. Laplace Transform of f(t) = cos (pt + q) is

s sin q − p cos q s sin q + p cos q

(C) e −100 α + e −200 α (D) e −200 α − e −100 α

point (1, −2, 2) on the surface is given by

(A) 0.256i + 0.683j + 0.256k (B) 0.683i + 0.256j + 0.683k

highest temperature (in  C ) on the circumference of the circle x2 + y2 = 1 is

The value of the determinant of the matrix is

38. The real root of the equation x. ex = 2 is evaluated using Newton−Raphson’s

(A) 34.64 (B) 60.00 (C) 69.28 (D) 74.64

(A) 0.532 (B) 2.53 (C) 5.85 (D) 59.2

42. A rectangular key of size 10 mm x 8 mm and length 40 mm is used to mount a

46. In a 10 mm diameter die cavity, metal powder is compacted to a height of 15 mm.

47. A flat surface S can be machined on a

49. For machining the circular are shown

in the figure below on a NC machine,

(A) I = 0, K = R, X = − (R−P), Z = −Q (B) I = R, K = 0, X = − (R−P), Z = Q

45  and auxiliary cutting edge angle = 10  . If the operation is carried out at a

52. A φ 20 mm through hole is to be drilled in a 30 mm thick plate using a double

machining a job of diameter 30 +−00..10

62. The precedence diagram of 10 elements to be included in the design of an

i Personal needs allowance: 4% of basic time

The work content of the job is

Rule 1 Rule 2 Rule 3 Rule 4

(A) Rule 1 & Rule 2 (B) Rule 1 & Rule 3

Q. Time to market 2. Ergonomics

Automation Strategy Type of

Mechanism of Material Removal Process

Common Data Questions

Common Data for Questions 79, 80

Linked Answer Questions: Q.81a to Q.85b carry two marks each

Statement for Linked Answer Questions 82a & 82b

82a. The velocities (in m/s) at sections 1 and 2 will respectively be

Statement for Linked Answer Questions 83a & 83b

Statement for Linked Answer Questions 84a & 84b:

Statement for Linked Answer Questions 85a & 85b :

5. (B) 6. (D) 7. (C)

where h f = pressure head loss due to friction.

10. (B) 11. (D) 12. (D)

13. (C) 14. (D)

σ = 1400 (0.33) 0.33 = 971MPa

Basic Model for Allowances