LECTURER IN PRODUCTION ENGINEERING

LECTURER IN PRODUCTION ENGINEERING

TECHNICAL EDUCATION (ENGG.COLLEGES)

(CATEGORY NO. 370/2010)

Examination Date

01/12/2011 Thursday 08.00 AM to 09.15 AM

Number of Candidates :- 617

 (Maximum Marks : 100)

(Duration: 1.15 Hours)

( Medium of Questions: English )

Syllabus:  An Objective Type Test (OMR - Valuation) based
on the qualification prescribed for the post

1.   METALLURGY AND MATERIAL SCIENCE

Classification of engineering materials-selection of materials with reference to

properties, service and economic considerations.  Thermal, Physical Mechanical,

Electrical, Magnetic, Dielectric Properties, Super conductivity and Super Plasticity of

materials.  Metallic bonds, crystal structure, space lattice, types of unit cells, Miller

indices, co-ordination number, atomic packing factor, allotropy and polymorphism,

imperfections in crystals.  Elastic and Plastic deformation of metals, Factors affecting

plastic deformation, deformation temperature.  Slip, Twinning, Dislocation, Critical shear

stress, Frank-Read source, Strain hardening, De-lamination theory.

Diffusion mechanism, Fick’s Laws.  Theory of alloys, Gibb’phase rule, Solid

solutions.  Hume Rothery’s rule.  Equilibrium diagrams-Construction and usesEquilibrium diagram of binary alloys: Eutectic, Eutectoid, Peritectic and peritecoid

reactions.   Iron-Carbon Equilibrium diagram, Isothermal TTT diagrams, Critical cooling

rate.  Heat treatment processes, Hardenability tests.  Surface treatments, Case Hardening,

Carbursing, Nitriding, Cynading, Induction hardening, Precipitation hardening, CVD,

PVD, Thermal spraying, Plasma spraying, D-Gun spraying, Recovery, Recrystalisation

and Grain Growth.  

Testing of materials – Tensile and Compression test, Impact test, Significance of

fracture mechanics, Brittle fracture, Griffith’s crack theory, Energy balance approach,

Ductile fracture, Factors leading to crack formation, Ductile-brittle transition in steels,

Fatigue mechanism, Fatigue crack growth, Creep mechanism.  Properties, composition

and uses of various types of Cast Iron and Steels – Effect of various alloying elements.

Properties, composition and uses of Copper, Aluminum, Titanium and its alloys, Effects

of various alloying elements.  Introduction to Ceramics, Composites.  Smart materials.

Nuclear.  Nano materials.

2.  PRODUCTION PROCESS-I

General Introduction to classification of production process: Foundry: Pattern

making, pattern materials, pattern allowances, types of pattern, pattern design.  Sand

moulding procedure, types of sand moulding and moulding sand, ingredients and the

properties of moulding sand, sand conditioning and reclamation.  Core making: types,

properties and ingredients of core sand.  Sand testing methods.  Solidificatin of castings:

Mechanism of dentritic growth, solidification rate and time, Chvorinov’s rule.  Gating

and resering: functions of gating and risering system, gating system, design of sprue,

gating ratio.  Riser design, riser shake, size and location.  Casting defects: causes and

remedies.

Special casting process: Permanent mould casting, shell moulding, CO2 process,

Expandable pattern casting (lost form).  Precision investment casting, centrifugal casting,

die casting, die casting alloys.  Rolling: Principles of metal rolling, Rolling mills and

their classification, Semi-finished and finished roll products.  Roll passes, Defects in

rolling special products like tube, wheel and tyre.  HERF – Explosive forming, Hydro

forming, Electromagnetic forming.

Forging: Classification of forging, smith forging, drop forging, press forging,

upset forging, forging process, forging hammer and forging press.  Forging dies,

characteristic forged products, forging defects.  Press working, process involving

shearing, bending, drawing and squeezing application.  Extrusion: process, methods and

applications.  Drawing of rods, wires and tubes.  Processes and applications of metal

spinning and stretch forming processes.

3.  PRODUCTION PROCESS-II

Classification and general consideration of metal joining techniques-Pressure

Welding Process; Cold welding & electrical resistance.  Types of joints& edge

preparation in welding process.  Gas welding: Principles of gas welding Oxy – Acetylene

welding.  Principle of operation.  Types of welding flames.  Joint design, welding

technique, filler materials & fluxes, welding equipments.  Oxy-Acetylene welding, safety

precautions in gas welding.  Field of application of gas welding, gas cutting.

Electric arc welding: Principle of arc welding, A.C. & D.C. welding equipment.

Straight & reverse polarity Principle, equipment, joint design, advantages, disadvantages

& application of arc welding, metal arc welding, submerged arc welding.  TIG & MIG

welding.  Atomic Hydrogen welding, welding electrodes-consumable & non-consumable,

rare and coated, electrode coding.  Resistance welding processes-their principle-types –

spot, seam, projection, percussion and flash welding.  Soldering & brazing: Methods &

applications.

Electro slag welding, plasma arc welding, electron beam welding, laser beam

welding, ultrasonic welding, thermal welding, diffusion welding, under water welding,

welding of dissimilar metals, welding of plastics.  Thermal effects of welding on weldedjoints.  Microstructure of welded joints, Heat affected zone, Weldability of cast iron,

plain steels and aluminum.  Testing of welded joints: Destructive testing of weldments –

Strength, hardness and fuctility, Non destructive testing of weldments – ultrasonic dye

penetrant, magnetic particle inspection, X ray testing procedures.  Residual stresses and

stress relieving techniques, Welding symbols, Defects in welding – their causes and

remedies.

4.   MACHINE TOLLS – I

Introduction to metal removal process – types of machine tools, Lathes: Engine

Lathes – specification-general study of main parts and tool and work holding devides,

lathe operations and cutting tols used, speed and feed for turning, turning time

calculations.  Types of lathes-Capstan, Turret, Copying.  Automatic and semi-automatic

lathes – their working principles, applications and essential difference from engine lathe.

Shaping, planning, and slotting machines – specifications, main parts and

functions, operations, work and tool holding devices, drives adopted and tools used.

Drilling machines-types and specifications, main parts and functions, operations, work

and tool holding devices, drilling tool nomenclature, deep hole drilling, reaming.  Boring

machines-main parts and functions, boring machines, operations, examples of work done.

Milling machines-types and specifications, main parts and functions, milling

operations, types of milling cutters, indexing-simple, compound and differential.  Milling

of spur and helical gears.  Grinding machines – main parts and functions, plain,

cylindrical grinding, centreless grinding and surface grinding operations.  Honing and

lapping.  Cutting action of grinding wheels-Cutting speed and feeds-coolants usedFactors governing wheel selection-blocking  and dressing.  Thread grinding, profile

grinding, tool and cutter grinders.

5.  MACHINE TOOLS – II

Broaching machine: Description, types and specifications.  Broaching: Broaching

machines: push, pull, surface and continuous broaching machines, broach construction,

Operations-keyway broaching, external and internal spline broaching, surface broaching.

Gear manufacturing – methods of manufacturing; moulding, forming and cutting, their

merits and demerits.  Gear generating – principles of gear hobbing, gear shaping, and

gear finishing.  Finishing operations-lapping, honing, super finishing and burnishingdescription, methods, and tools employed.

Unconventional methods of machining: principle of working, areas of

applications and characteristics of the following operations.  EDM, ECM, CHM, LBM,

EBM, AJM, USM, PAM, Water jet cutting.  Machine tool drives-electrical, mechanical,

hydraulic and combination systems – advantages and disadvantages.  Materials for

machine tool structures.  Machine tool rigidity, sources, effects and elimination of

vibration in machine tools. Hydraulic circuits, fundamentals of hydraulic circuits – type of pumps, valves etc.

hydraulic circuits for feed and cutting motion.  Hydraulic copying system.  Powder

metallurgy – Manufacture of metal powders, Powder compaction – Mechanical, thermal

and thermomechanical compacting processes, Sintering mechanism.  Manufacturing and

application of important P/M components.  

6.   MACHINE THEORY AND DESIGN

Definitions-design principles-common engineering materials and their propertiesstresses in machine parts-Tension, compression, shear-elastic constants-safe stress-factor

of safety-bending & Torsion – combined stress-theories of failure – stress concentration –

variable stresses-endurance limit-fatigue  Factor – Combined steady & variable stressGerber, Goodman & Soderberg method-impact stress & strain energy.  Shafts-torsion &

bending of shafts – hollow shafts – Design of shafts for strength & stiffness-Effects of

Keyways-Propeller shafts.

Design of – pins, keys, splines, cotters, Design of Bolted joints, Design of

threaded fasteners & power screws, shaft couplings-design of rigid & flexible couplings.

Welded joints –types of joints - strength of welds – fillet welds – stress concentration in

welded joints – eccentric loading.

Springs – classification and uses of springs – spring materials – design of helical

springs – effect of end turns – energy absorbed – deflection – design for fluctuating loads

– vibration in springs – buckling of springs.  Design of leaf springs.  Pressure vessels –

air receivers – thin and thick cylinders – engine cylinder – Design of pipes and pipe

joints.

7.   COMPUTER INTEGRATED MANUFACTURING SYSTEMS

Product development cycle-Application of computer for design (CAD),

manufacturing (CAM) and integration of CAD/CAM – Elements of Computer Integrated

Manufacturing (CIM) Systems – Product design to marketing.  Various activities in CIM

– From product design to marketing.  Sequential and concurrent engineering – Concepts

and features.

Group Technology – Part family, identification, classification and coding –

OPITZ  and MICLASS systems. Benefits of GT – Computer Aided Process Planning

(CAPP) – Retrieval and regenerative approaches, benefits; structure of a process planning

software.  Process capability. Introduction to CAM – Numerical Control (NC), CNC,

DNC system – Definition, types, basic components and principle of operation.  Accuracy

and repeatability.  Features of CNC systems – Absolute and incremental, preparatory and

miscellaneous codes, interpolation and canned cycle, tool compensation.  Simple turning

and drilling programs only.  Adaptive control – concept, feasibility and strategies –

Adaptive Control Constraint (ACC) and Optimization (ACO).Flexible Manufacturing System (FMS) – Components, types.  FMS work stations.

Industrial robot – Basic elements, classification, physical configuration and applications

of industrial robots.  Resolution, accuracy and repeatability.  Computer Aided Inspection

(CAI) and Testing (CAT) – Effects of implementing CAI and CAT.  Non-contact optical

methods for CAI – Machine vision, scanning laser beam, photogrammetry.  Co-ordinate

Measuring Machine (CMM) – Working and configurations of contact and non-contact

CMMs.  Rapid Prototyping (RP).  Concept and methods – Stereolithography (SL), Solid

Ground Curing (SGC), Fused Deposition Modelling (FDM), selective Laser Sintering

(SLS), 3D printing.

8.   THEORY OF METAL CUTTING

Introduction to metal cutting and metal removal processes, classification of

cutting tools, geometry of single point and multi point cutting tools, tool nomenclature –

ASA and ORS systems – inter relationship.  Effect of tool geometry in metal cutting.

Mechanism of metal removal – Primary deformation on shear zone and Secondary

deformation on rake face – Chip formation, types of chip, BUE formation – Friction in

metal cutting – methods to reduce friction – chip breaker.

Orthogonal and Oblique cutting – Mechanics of orthogonal cutting – Forces of

deformation – shear angle, its importance – Stress distribution on rake face –

Determination of shear angle and chip thickness ratio – Forces relations – Merchants

circle diagram – Influence of speed, feed, and depth of cut in cutting – related simple

problems.  Shear plane theory, Lee and Shaffer principle.  Dynamometers – force

measures-Turning, milling, and drilling dynamometers. Heat in metal cutting-Zones of

heat generation-variables affecting the tool temperatures – tool-work thermo couple,

embedded thermocouple, Experimental techniques for measuring tool temperatures. 

 Cutting tool materials – Desirable properties of tool materials-major tool

materials – Carbon steels, HSS, Coated tools, Cemented carbide, Ceramics, CBN, and

Diamond – their characteristics and applications.  Tool wear and tool life – Wear

mechanisms, types, tool failure, crater wear, flank wear – Tool life criteria-Taylors tool

life equation, modified tool life equation, parameters affecting tool life-problems.

Machinability – various criteria for machinability index – Optimum cutting speed.

Cutting fluids – Types and applications.

9.   MACHINE TOOL DESIGN

General requirements of machine tool design – Design of spindles – functions and

requirements – materials for spindles.  Design of Bearings – Journal bearings – hydrodynamic lubrication-petroff’s equation-Bearing characteristic number –Summerfield

number-L/D ratio-clearance ratio-minimum film thickness-oil flow through bearings.

Ball & roller bearings-types-static & dynamic load capacity – equivalent dynamic loadbearing life-selection of bearings.Gears-Nomenclature-Lewis equation – Lewis form factor-velocity factor-working

stress in gear teeth – dynamic load on gear teeth-design of spur gear, helical gear, bevel

gear & worm gear checking of dynamic tooth load.  Wear tooth load,  endurance load.

AGMA standards-design of shafts for AP, GP & LP.  Standardization of speed & feeds –

structure & ray diagrams for machine tool gear boxes-gear design & analysis.

Design of machine tool structure-functions of machine tool structure and their

requirements.  Design criteria-materials-static & dynamic stiffeners-profiles of machine

tool structures-basic design procedure in machine tool structures-design of beds &

columns, bases & tables, cross rails, arms, saddles & carriages, rams, model techniques.

Design of guide ways-functions and types-design of slide ways-design criteria and

calculations for slide ways-design of anti-friction guide ways.

10.   TOOL ENGINEERING

Jigs and fixtures – Necessity for jigs and fixtures – Elements of fixtures, design

considerations, locators, types of locators, clamping and guiding devices, swarf disposal

methods.  Work holding devices for flat, round and irregular surface, - Design of drill

jigs, bush specifications.  Fixture for lathe operations, milling, broaching and welding

fixtures, fixtures for CNC machines, modular fixtures.

Press work tools, blanking and piercing tools, load variation during blanking –

Calculation of press tonnage for blanking and piercing.  Types of dies, simple,

compound, combination and progressive dies.  Design of compound and progressive dies.

Bending and drawing dies: Bending allowances, bending methods.  Bending pressurecalculation of blank size and press tonnage for drawing, metal flow during drawing

operations.  Fine blanking, Embossing and Coining.

Tool for forging, Design of drop forging dies – Rolling, strip rolling theory, stress

distribution in rolling, Roll separation force and torque.  Forces acting on single point and

multiple point cutting tools.  CAD for tooling: Turret press FMS-Computer applications

(CAD/CAM) in short metal press work – Quick die change method – Single minute

exchange of dies – group tooling – Design of single point tools – Plastic as a tooling

materials – Fluidized bed fixturing.

11.   PRODUCT DEVELOPMENT AND DESIGN

Definition of a product – Types of product – levels of product – New product

development-product-market mix-New product development (NPD) process – Idea

generation methods-Creativity – Creative attitude, creative design process –

Morphological analysis – analysis of interconnected decision areas, brain storming,

synectics.  Product life cycle – The challenges of product development – product analysis

– product characteristics-economic considerations-production and marketing aspects.

Characteristics of successful product development.  Phases of a generic product

development process – Customer need identification.  Product development practices andindustry-product strategies – time to market-analysis of the product-standardizationsimplification and specialization.  

Product design-definition-Design by evolution – design by innovation – design by

imitation – factors affecting product design.  Standards of performance and

environmental factors, decision making and iteration – Morphology of design (different

phases) – role of aesthetics in design.  Introduction to optimization in design – economic

factors in design-design for safety and reliability.  Role of computers in design –

modeling and simulation – the role of models in engineering design – mathematical

modeling – similitude and scale models.  Concurrent design – Six sigma and design for

six sigma.  Introduction to optimization in design – economic factors and financial

feasibility in design – Design for manufacturing, Rapid proto typing (RP) – application of

RP in product design.  Product Development versus Design.

Design of simple products dealing with various aspects of product development

and design starting from need till the manufacture of the product.

NOTE: - It may be noted that apart from the topics 

detailed above,

questions from other topics prescribed for the

educational qualification of the post may also appear

in the question paper. There is no undertaking that

all the topics above may be covered in the question

paper.