SENIOR MECHANIC

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Part-I Questions based on Diploma in Mechanical Engineering
I. INDUSTRIAL MANAGEMENT
Principles of management: Meaning of management – Taylor’s scientific.
management, Functions of management – Different types of ownership –
Organizational structure.
The principles of a good wage payment system: Types of wages – Nominal, real,
living, fair, and minimum wages – Incentives
Quality Planning and its developments: Definitions of quality– Dimensions of
quality– TQM concept
Project Management Techniques: Introduction to Network analysis – Commonly
used terms in CPM and PERT – CPM – Operation, earliest finish time (EFT), latest
finish time (LFT), critical path, event, slack or float, dummy activity – Construction
and numbering of network diagram – Fulkerson's rule – Simple problems on CPM (by
AOA method only) – PERT - Comparison between CPM and PERT – Calculation of
expected time – Event, activity, successor event, predecessor event, earliest expected
time, latest allowable time, slack.
Quantitative techniques in management: Methods –Linear programming: -
Formulation of LPP –Transportation problem – North West corner rule, Vogel's
approximation method – Simple problems. – Game theory – Two-persons zero sum
game – Maxi-min and mini-max principle – Saddle point – simple problems.
Materials and sales management.
Inventory management –definition and classification –purchase procedure –buying
techniques –EOQ and ABC analysis.
Stores management –introduction –store keeping functions –duties of store keeper –
store layout

Centralized and decentralized store –store records –indent forms –bincard –store
ledger.
Sales –importance –functions of sales department –sales forecasting.
II. INDUSTRIAL ENGINEERING
Production planning and control: Concepts of industry – Meaning of the term
production and productivity – Methods of increasing productivity – Types of
production – Job production batch production, mass production,
continuous production – Explanation of production planning control – Benefits and
functions of PPC – Pre-planning activities – Forecasting, plant location, product
planning, design and development, material selection,
Process planning, determination of men, machines, material and tool requirements –
Process planning –Choice of machine in process planning – Break even analysis –
Process sheet –Process planning procedure
Routing – Scheduling – Dispatching – Value Engineering – Plant location and layout
– Factors to be considered in locating industrial plants – Plant layout – Types of
layouts – Compare the advantages and disadvantages of each type – Plant
maintenance – Types of maintenance.
Method study: Work study – Advantages and application of work study to increase
productivity

Method study – Therbligs and their symbols – Process chart symbols – Preparation of
operation process chart, flow process chart, man-machine chart, right hand left hand
chart, and simo chart – Flow diagram – Principles of motion economy – Rules
concerning human body, work place layout and material handling, tools and
equipment design – Objectives of work measurement – Procedure of stop watch time
study – Standard time calculation – Production study – Work sampling – Steps in
work sampling.
Inspection and Quality control: Concept of quality and quality control – Product
control – Concepts of inspection – Types of inspection – First piece inspection,
working inspection, sample inspection, operation inspection, key operation inspection,
floor or patrolling inspection , centralized inspection – Advantages and limitations
Fundamental statistical concepts: Explain the term variability in measurements –
Explain the terms variable, attribute, frequency, frequency distribution and frequency
plot – Normal distribution curve – Tally sheet – Explanation of the terms mean, mode,
median and standard deviation – Calculation of mean, mode, median and standard
deviation –Statistical quality control -- Types of control charts – X,R,P,100P, and C
Project analysis: Need and scope for project analysis - Explanation of the
constituents elements of project analysis – Production cost – Market survey – Selling
price – Capital investment – Return on, investment – Elements of costing –
Classification of costs – Depreciation – Types of depreciation –Obsolescence – Basic
formula for calculation of machining times for the operation such as turning, drilling
and shaping – Simple problems.
III. METALLURGY AND MACHINE TOOLS
1. MATERIAL SCIENCE:
Metals and alloys: Structure of materials – Structure of solids – Crystal structure –
BCC , FCC and HCP -- Ferrous and non ferrous – Cast iron- White, malleable, grey
and nodular cast iron –Manufacturing of Pig iron- Blast Furnace – Manufacturing of
Cast iron - Cupola Furnace – Types of steel – Manufacturing of steel - Bessemer
process, LD process, Open hearth and Electric furnace – Steel alloys -- Non ferrous
metals and alloys - Aluminum, Copper and its alloys – Crucible furnace.
Heat Treatment Processes: Cooling curve for pure iron– iron carbon equilibrium
diagram –TTT diagram – Micro constituents of steel -- Heat treatment process,
annealing, normalizing, hardening, tempering, mar tempering, austempering, case
hardening (cyaniding, nitriding and carburising ), age hardening—induction hardening
– flame hardening -- residual stress due to heat treatment
Properties, testing and inspection of materials: Mechanical properties such as
strength, hardness, toughness, brittleness, creep, fatigue, stiffness, ductility,
malleability, elasticity and plasticity – Thermal properties such as specific heat,
thermal conductivity, thermal resistance, and thermal diffusivity – Destructive testing

--Tensile and compressive test – Hardness test: – Impact test – Fatigue test – Creep
test – Non-destructive testing – Radio graphic – Ultrasonic testing – Inspection --
Spark test, magnetic particle, x-ray and dye penetration tests
2. MANUFACTURING PROCESS.
Measuring instruments, gauges and comparators: Classification of measuring
instruments – Precision and non precision instruments – Direct reading and indirect
measuring instruments –– Vernier caliper, micrometer (inside, outside) -
Classifications of gauges – Plug, ring, snap, screw pitch gauge, feeler gauge, standard
wire gauge and indicating gauges –Comparators – Mechanical comparators, Electrical
comparators, Optical comparators, Pneumatic comparators.
Welding, soldering and brazing : Arc welding –Principle of arc welding – Welding
positions –– Flat, horizontal , vertical and overhead welding – Welded joints – Butt,
lap ,corner , tee ,edge ,V- joints, U-joint --Selection of welding electrodes – Electrode
coatings – Functions of Electrode coating – Gas welding --Type of flames –
Functions and operation of oxy –acetylene cylinders, pressure regulators, welding
torch, nozzle – Explanation of submerged arc welding, tungsten inert gas (TIG)
welding, metal inert gas (MIG) welding, Atomic hydrogen welding and thermit
welding – Defects in welding – Causes and remedies of the defects such as porosity,
poor penetration, warping, under cut, distortion crack, poor appearances - Soldering –
Brazing.
Foundry: tools- rammer, trowel, slick, lifter, strike off bar, bellow, sprue pin, mallet,
gate cutter, swab, vent rod, draw spike, moulding box – Composition of moulding
sands – Types of moulding sand – Green sand, dry sand, parting sand, loom sand,
facing sand and core sand – Properties of molding sand such as porosity, plasticity,
adhesiveness, cohesiveness, refractoriness. Types of patterns- single piece pattern,
split pattern, match plate pattern, gated pattern, loose piece pattern, sweep pattern –
Pattern allowances- shrinkage allowance, draft allowance, machining allowance,
distortion or camber allowance, rapping allowance
Bench work and fitting: Fitting operations like chipping, filing, scraping, grinding,
sawing, marking, drilling, reaming, tapping, dieing – Tools used in fitting- vice (bench
vice, pipe vice, hand vice), files- various types of files-specification of files-chisels,
hammers, hack saw, scrapers, punches, surface plate, surface gauge, V-block, angle
plate, try square,combination set, steel rule, calipers(outside and inside), divider,
scriber, drills, , reamer, tap and tap wrench, die and die stock, goggles.
3. MACHINE TOOLS
Metal cutting :Orthogonal cutting and oblique cutting, chip formation ,type of chips,
cutting speed , feed and depth of cut --Tool life – Machinability
Lathe and lathe work: Type of lathe –Lathe parts, function of each part – Lathe
accessories – Work holing and tool holding devices.– Speed, feed and depth of cut –
Operations – taper turning methods, – Lathe specification
Drilling machines: Classification – Work holding devices – Types of drill bits –
Tool holding devices – Operations.
Shaping Machines : General use of a shaper – Parts and their functions.
Slotting Machines: General use of a slotter – Slotter parts and their functions.
Planing machines: General use of a planer – Planner parts and their functions.
Milling machines: General use of milling machines – Parts of milling machines and
their functions – Types of milling machines - Cutter holding devices (a) arbours (b)
collets - Milling operations - plain milling, key and key ways, gang milling , T – slot
milling – Milling methods (a) conventional milling (b) climb milling – Types of
indexing.
Broaching Machines: General use of a broaching machines – Parts and their
functions.
Gear manufacture: Method of making gears – Gear hobbling.
Jigs and Fixtures: Definition of jigs and fixtures.
Grinding: Abrasives- natural, artificial – Bonding materials -vitrified, silicate,
shellac, rubber –
Kind of abrasives, grain size, grade and structure, kind of bond material, functions of
the grinding wheels – Grinding machines – Cylindrical grinders.-centre type and
centre less type grinders.
Capston and turret lathe : Construction and parts – tooling layout
Automatic and copying machines : Automation – definition
Flexible manufacturing system : Flexible automation – flexible manufacturing cell –
components of FMS
Robots and robotics : Basic elements of robots – types of joints – robotic arms –
robotic hands
Computer Numerical Control (CNC): Machine tools ( brief description only)
IV: FLUID MECHANICS,PNEUMATICS AND HYDRAULIC MACHINES
1. FLUID MECHANICS AND PNEUMATICS
Properties of Fluids :Density – specific weight – specific volume – specific gravity –
problems – viscosity – kinematics viscosity –Newton’s law of viscosity – types of
fluids – compressibility – surface tension – capillarity
Fluid pressure and its measurement: Fluid pressure at a point – pressure head –
problems – Pascal’s law – absolute, gauge, atmospheric and vacuum pressures –
simple problems – measurement of fluid pressure – Piezometer tube – simple
manometer– differential manometer – inverted differential manometer – Bourdon’s
tube pressure gauge – total pressure.
Kinematics and Dynamics of fluid flow: Introduction – types of fluid flow – steady
and unsteady flow –uniform and non-uniform flow – laminar and turbulent flow –
compressible and incompressible flow – rotational and ir-rotational flow – rate of flow
or discharge – equation of continuity of a liquid flow – simple problems – energy of a
liquid in motion – potential energy – kinetic energy – pressure energy – total energy –
total head of liquid in motion – Bernoulli’s equation –– practical applications of
Bernoulli’s equation – venturimeter – Orifice meter – Pitot tube.
Flow through Orifices, Notches, Pipes and Nozzles: Orifices – types of orifices –
Vena contracta – coefficient of contraction – coefficient of velocity – coefficient of
discharge – Notches – types of notches – Flow through pipes – loss of head in pipes –
major energy losses – minor energy losses – loss of energy due to friction – Darcy’s
formulae(No derivation) for loss of head in pipes – Chezy’s formula (No derivation)
for loss of head in pipes – simple problems – loss of head due to sudden enlargement
– loss of head due to sudden contraction(No derivation) – water hammer -- nozzles .
Fluid Power: Introduction – Basic law – Applications of fluid power
Hydraulic system: Basic elements of hydraulic system – Oil reservoir pump unit –
Principles of working of Positive displacement pump – Classifications – Gear pumps,
Screw Pump, Vane pumps, Lobe pump, Simple piston pumps.
Hydraulic control elements and components: Control valves – Functions –
classifications – Describe the working of pressure control valves such as relief valves
- poppet valve – Direction control valves– check valves.
Flow control valves – types – gate, globe, butterfly valves, non return valve.
Pneumatic System: Comparison of pneumatic system with hydraulic system –
identification of standard pneumatic symbols – basic pneumatic system – air filter –
pressure regulator – lubricator – mufflers
Pneumatic control elements and components: Pneumatic control valves – Air
cylinders.
2. HYDRAULIC MACHINES
Impact of jets : Force exerted by the jet – stationary – vertical – inclined – curved
plate ( symmetrical and unsymmetrical ) – force exerted by the jet on moving plates –
simple problems.
Impulse turbines: Development of water Turbines-classification-impulse Turbine-
Pelton wheel Components.
Reaction turbines: Components—difference between impulse& Reaction—
Classification of ReactionTurbines—Francis Turbine—Kaplan Turbine -Draft tubes –
specific speed.
Centrifugal pump: Types of casing—piping system of CP—work done, manometric
head—efficiencies–discharge—power required to drive –multistage pumps -specific
speed of CP— cavitation—priming.
Reciprocating pump:Types –comparison of CP & RP –discharge—slip –air vessels ,
Hydraulic ram.
V. APPLIED MECHANICS, STRENGTH OF MATERIALS AND DESIGN
OF MACHINE ELEMENTS
1. APPLIED MECHANICS , STRENGTH OF MATERIALS (5 marks)
Direct Stresses and strains: Types of stresses and strains – tensile and compressive –
longitudinal and lateral strain –Poisson’s ratio – behaviour of mild steel under tension
– stress strain diagram – limit of proportionality – elastic limit – yield point – ultimate
stress – working stress – factor of safety – comparison of stress strain diagram of a
mild steel and a brittle material– Hooks law and Young’s modulus – principle of super
position – stresses in varying section – stresses in composite section – simple
problems.
Shear stress and shear strain: Shear stress and strain – modulus of rigidity –
volumetric strain, bulk modulus – simple problems
Thermal Stress and strain: Nature and magnitude of stresses due to change in
temperature – total or partial prevention of expansion and contraction – temperature
stress on composite bar– simple problems.
Truss analysis : Types of frames – formula for finding the redundancy—free body
diagram – equilibrium – forces in various members of stress due to loading – method
of joints and method of sections
Friction: Introduction – type of friction – static friction, dynamic friction, sliding
friction, rolling friction, pivot friction, limiting friction, angle of friction, coefficient of
friction, cone of friction – state laws of friction. – static friction and kinetic friction.
Centre of gravity of sections: Centroids – centre of gravity – axis of symmetry and
axis of reference – methods to find center of gravity – simple geometric sections such
as rectangle, triangle and circle. Moment of inertia of sections: Moment of inertia –
radius of gyration.
Riveted joints: Types – lap joint – single riveted, double riveted ( chain and zigzag )
– butt joint – single cover single riveted, double cover single riveted – failure of
riveted joints – failure of rivets – shearing and crushing – failure of plates – tearing
across a row of rivets – tearing off plate at an edge – strength of rivet, plate and
riveted joint – efficiency of a riveted joint. – caulking and Fullering operations.
Welded joints: welding terms – leg of the weld, size of the fillet weld,
throat thickness, effective length of the weld, side fillet weld and end fillet weld –
strength of welded joints.
Thin Cylinders: Failures of thin cylinder – stresses in thin cylindrical shell – hoop
stress – longitudinal stress.
Torsion of circular shafts: Torsion equation – strength equation for solid and hollow
shaft ( no proof ) – power equation – polar moment of inertia.
Springs: Types of spring – leaf spring – helical springs.
Shear force and bending moment: Types of beams – cantilever beam, simply
supported beam, over hanging beam, built in beam or fixed beam and continuous
beam – types of loading –– concentrated or point load, uniformly distributed load and
uniformly varying load – shear force and bending moment diagrams – cantilever
beams – point load, uniformly distributed load and combination of point load and
uniformly distributed load – simply supported beam – point load, uniformly
distributed load and combination of point load and uniformly distributed load –
maximum bending moment on the section. – deflection of beams
Columns and struts: Column, strut, buckling load, equivalent length, slenderness
ratio – types of columns – short column, medium size column, long column.
2. MACHINE DRAWING AND DESIGN OF MACHINE ELEMENTS
Screw Threads: Thread terminology– Forms of screw threads (Square thread, V
thread) – Wit worth thread– British Association thread–American standard thread–
Acme thread–ISO metric thread–square thread–single start and multi start threads–
right hand and left hand threads–conventional representation of threads-bolted
connection using standard proportions..
Welded joints and piping layout: Classification of welds- Elementary welding
symbols -- Types of pipes – Methods of connecting pipes-pipe threads-Representation
of pipe threads – Types of pipe joints – Single and double line orthographic symbols
for pipe fittings and valves (flanged, screwed and welded joints).
Limits, Fits and Tolerances: Definition of limits, fits and tolerances.
Surface Roughness: Surface roughness terminology- surface roughness values,
Grades and symbols.
General design considerations: General procedure – Design stress and working
stress – factor of safety.—kinematic link – pair – chain – four bar chain – examples
and applications – mechanism -- inversion
Bolts, Nuts and Key: Designation of screw threads – stresses in screwed fastenings
due to static loading – initial stresses – stresses due to external forces – bolts of
uniform strength – types of keys – forces acting on a sunk key – strength of a sunk key
– calculation of key size using empirical proportions.
Shafts: Torsional stresses and strains – strength of solid and hollow shaft – design of
shaft considering strength and rigidity– comparisons – power transmitted by shaft –
Compare solid and hollow shaft in terms of their weight, strength and stiffness.
Couplings: Shaft couplings – requirement – types.
Bearings: Functions of bearings – classification of bearings – Radial bearings – thrust
bearings – sliding contact bearings – rolling contact bearings.
Cams: Classification of followers and cams – motion of the followers – uniform
velocity, simple harmonic motion – uniform acceleration and retardation – cam
terminology – displacement diagrams.
Governors and Flywheels: Functions of the governors – types of governors – simple
watt governor – porter governor – flywheels – comparison with governors –
coefficient of fluctuation of speed – fluctuation of energy – maximum fluctuation of
energy – coefficient of fluctuation of energy.
Belt Drives: Types of belts – flat belt, circular belt or rope, V-belt – types of flat belt
drives – open and crossed belt drive – compound belt drive – stepped or cone pulley
drive – velocity ratio – slip – creep.
Gears and Gear Trains: Functions of gears – friction wheels – advantages and
disadvantages of a gear drive – spur gear nomenclature – simple gear drive – velocity
ratio – gear trains – simple gear train – compound gear train.
VI. THERMAL ENGINEERING THERMAL ENGINEERING
Air Standard Cycles: Assumption, Air standard efficiency -- explanation with
diagrams and derivation of air standard efficiency of Carnot Cycle, Otto cycle, Diesel
cycle, dual combustion cycle
Fuels & Combustion: Classification of fuels-solid, liquid, & gaseous- Merits &
demerits of various types of fuels -- Requirements of a good fuel.-- Calorific Value -
- combustion of fuel
Testing of I.C. Engines: Performance of I.C.Engines- testing- Indicated power, Brake
Power, Friction Power, - Mechanical Efficiency- Indicated Thermal efficiency, Brake
Thermal efficiency, Relative efficiency-Total fuel consumption & Specific Fuel
Consumption-Morse test for Determination of I.P. of multi-cylinder engine- Heat
balance sheet- problems
Heat Transfer: Heat Transfer- conduction, convection and radiation – Fourier’s law –
Thermal conductivity – Conduction through plane wall and composite wall– Black
body concept – Stefan - Boltzman law -- Gray body concept – Newton Rikhman
equation – free and forced convection
Heat Exchangers: Heat exchangers-Classification– Recuperator type and
regenerative type, parallel flow, counter flow type & cross flow. – concept of over all
heat transfer coefficient --LMTD
Air Compressors: construction and working of Air compressors- function of an air
compressor- uses of compressed air -Classfiication of the air compressors- working of
reciprocating compressors (single stage and two stage), rotary compressors - fans and
blowers, centrifugal compressors and axial flow compressors. Mechanical efficiency
& Volumetric efficiency
Different systems of I C engines: Fuel systems, - components – –carburetion –
functions of carburetor –working fuel systems of diesel engine –fuel filter – injector
and injection nozzle – ignition system –– cooling system – classification of cooling
system – radiators
I C engine lubrication system – forced system – governing systems– quantity
governing – quality governing – hit and miss governing.
Principles of Refrigeration:Definition of refrigeration, concept of C.O.P, unit of Refrigeration. reversed carnot cycle- COP, Application of refrigeration, C.O.P of vapour compression systems.
Vapour Compression Refrigeration systems: Principles and working of a vapour compression system with the help of flow diagram.
Refrigeration Equipments: Compressors - Condensers – Evaporators - Expansion
Devices: Capillary tube, Thermostatic expansion valve.
Refrigerants: Definition: Primary and secondary refrigerants, desirable properties of refrigerants
Psychrometry: Definition, Dry air, moist air, saturated, unsaturated and supersaturated air, degree of saturation, dry bulb temperature, wet bulb temperature, dew point temperature.
Psychrometric Processes: Sensible heating, sensible cooling –humidifying,dehumidifying
Air Conditioning: Definition, factors affecting human comfort, effective temperature
Air conditioning systems: Classification – industrial, comfort air conditioning, working of summer air conditioning, winter and year round air conditioning.
Part-II Questions based on Engineering Mathematics
I. Matrices – Identification of Matrices, matrix operations, adjoint and inverse.II. Determinants – Evaluation of second and third order, minors and cofactors, solutions of simultaneous linear equation in three unknown using Cramer’s  rule.III.Binomial Series – Expansions using Binomial theorem. IV. Trigonometric functions – Signs of functions in each quadrant. Trigonometric values of angles, properties of trigonometric functions, applications of the  identities sin( A ± B), cos ( A± B) and tan (A± B).
V. Coordinate geometry – Equations to a straight line – slope – intercept form,intercept form; Angle between two lines, condition for two lines to be perpendicular, parallel.
VI. Differentiation – Limits and continuity, derivatives of functions, equation to tangents and normals. Maxima and minima of functions of one variable.
VII. Integration of functions – Integration of different types of functions.VIII.  Applications of integration – Area bounded by a curve and X or Y axis,solutions of differential equations using the method of variable separable solutions of linear differential equations of first order.
Part-III Questions based on Basic Science (Physics & Chemistry)
Questions based on Physics & Chemistry (Diploma level).
Part-IV General Knowledge, Current Affairs, India National Movements & Renaissance in Kerala and its Leaders
Geography of India- Physical Features- Climate-Soils- Rivers- Famous Sites – Etc
Demography- Economic and Social Development-Poverty Alleviation-Economy and
Planning-Etc
History of India- Period from 1857 to 1947- National Movement- Etc.
Important World, National and Regional Events related to the Political and Scientific fields,
Sports, Cinema and Literature etc.
Facts about Kerala
Geographical Facts- Physical Features- Climate-Soils- Rivers- Famous Sites – Etc
Renaissance of Kerala
Important Events/ Movements/Leaders
Brahmananda Swami Sivayogi, Chattampi Swami, Sree Narayana Guru, Vagbhatananda,
Thycaud Ayya, Ayya Vaikundar, Poikayil Yohannan (Kumara Guru), Ayyankali, Pandit
Karuppan, Mannathu Padmanabhan, V.T.Bhattathirippad, Dr. Palpu, Kumaranasan,
Vakkom Moulavi, Blessed Kuriakose Elias Chavara, Etc
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.

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