BME MID QUESTIONS & ANSWERS

UNIT-1
U1_Q.1. Explain
1 the role of mechanical engineering in industries and society.

ROLE OF MECHANICAL ENGINEERING IN INDUSTRIES AND SOCIETY

Mechanical Engineering plays a fundamental and crucial role in both industries and society.
Here are some key roles of mechanical engineering in industries and society.

1. Product Design and Development: Mechanical engineers are at the forefront of designing and
developing products, ranging from consumer goods to industrial machinery and equipment. They
ensure that these products are functional, efficient, and safe for use.

2. Manufacturing and Production: Mechanical engineers work on optimizing manufacturing

processes, improving production efficiency, and reducing production costs. They are involved in
selecting the right materials, designing manufacturing systems, and implementing quality control
measures.

3. Automotive Industry: Mechanical engineers play a vital role in the design and production of
automobiles. They work on innovations in engine design, vehicle aerodynamics, safety features,
and fuel efficiency, contributing to the advancement of the automotive industry.

4. Aerospace and Aviation: Mechanical engineers are integral to the aerospace and aviation
sectors. They design aircraft, spacecraft, and their components, ensuring safety, reliability, and
performance. They also work on propulsion systems, materials, and aerodynamics.

5. Energy and Power Generation: Mechanical engineers are involved in the design and
maintenance of power plants, including those that generate electricity from fossil fuels, nuclear
energy, and renewable sources like wind and solar. They work on improving energy efficiency and
sustainability.

6. Environmental Sustainability: Mechanical engineers contribute to sustainability efforts by

developing energy-efficient technologies, designing eco-friendly products, and finding ways to
reduce waste and emissions in manufacturing processes.

7. Biomechanics and Medical Devices: In the field of healthcare, mechanical engineers work on the
design and development of medical devices, prosthetics, and rehabilitation equipment. They
apply their expertise to improve the quality of life for individuals with disabilities and medical
conditions.

8. Robotics and Automation: Mechanical engineers are crucial in the development of robotic
systems used in manufacturing, healthcare, agriculture, and other industries. They design robots
to perform tasks efficiently and safely, leading to increased productivity.

9. Infrastructure and Construction: Mechanical engineers in the design sod maintenance of

building, bridges, and infrastructure projects. They integrity, safety, and functionality.

10. Research and Innovation: Mechanical engineers engage in cutting-edge research to develop new
materials, technologies, and methods that drive innovation industries. They contribute to
advancements in science and technology.
11. Education and Skill Development: Mechanical engineering education and training programs
produce skilled professionals who go on to contribute to various industries, helping to drive
economic growth and technological progress

12. Societal Impact: Mechanical engineers play a role in addressing global challenges, such as climate
change, by developing sustainable technologies and solutions. They also contribute to disaster
relief efforts through the design of rescue equipment and shelters.
Technologies in Energy, Manufacturing, Automotive, Aerospace, and
U1_Q.2. 2
Marine sectors
TECHNOLOGIES IN DIFFERENT SECTORS: Mechanical Engineering plays a wide role in
Technology and Developments. Technologies in different sectors such as Energy,
Manufacturing, Automotive, Aerospace, and Marine sectors. Engineering
1. Energy Sector
 Renewable Energy: Improved solar panels, wind turbines, and energy storage make
renewable energy more efficient and affordable.
 Smart Grids: Enhance electricity distribution and integrate renewable sources.
 Nuclear Fusion: Research promises clean and limitless energy.
 Energy Storage: Advanced batteries, such as lithium-ion and solid-state, revolutionize storage
for grids and transport.

2. Manufacturing Sector
 3D Printing: Enables rapid prototyping, customization, and less material waste.
 IoT: Connects machines for real-time monitoring and predictive maintenance.
 AI and Machine Learning: Optimize production, quality control, and supply chains.
 Robotics: Automates tasks in assembly and material handling.
 Advanced Materials: Composites and smart materials boost durability and performance.

3. Automotive Sector
 Electric Vehicles (EVs): Improved batteries and charging infrastructure enhance EV adoption.
 Autonomous Vehicles: Advances in sensors and AI drive self-driving technology.
 Connected Cars: Features like remote diagnostics and infotainment improve user experience.
 Lightweight Materials: Carbon fiber and aluminum improve fuel efficiency and performance.

4. Aerospace Sector
 Advanced Propulsion: More efficient engines and alternative fuels reduce emissions.
 Aircraft Connectivity: In-flight Wi-Fi and communication systems enhance passenger
experience.
 Advanced Materials: Lightweight composites improve fuel efficiency and structural strength.
 Space Exploration: Innovations in rockets and robotics advance missions to the Moon and
Mars.
5. Marine Sector
 LNG Propulsion: Liquefied Natural Gas reduces emissions in shipping.
 Emissions Control: Scrubbers ensure compliance with environmental standards.
 Autonomous Vessels: Unmanned vehicles assist in mapping and inspections.
 Underwater Robotics: Enable deep-sea exploration and maintenance.
U1_Q.3. Explain
3 important mechanical properties of metals.

Definition: Materials are made up of matter. Materials are anything that have weight and occupy
some space

Mechanical properties of metals are as follows:

The knowledge of engineering materials and their properties is of great importance for a
design engineer.

1. Strength. It is the ability of a material to resist the externally applied forces without breaking or
yielding.
2. Hardness. Material hardness is the ability of a material to withstand force without scratching,
penetration, and indentation
3. Brittleness. It is the property of a material opposite to ductility. It is the property of breaking of
a material with little permanent distortion. Cast iron is a brittle material.
4. Stiffness. It is the ability of a material to resist deformation under stress. The modulus of
elasticity is the measure of stiffness.
5. Elasticity. It is the property of a material to regain its original shape after deformation when the
external forces are removed. This property is desirable for materials used in tools and machines.
It may be noted that steel is more elastic than rubber.
6. Plasticity. It is property of a material which retains the deformation produced under load
permanently. This property of material is necessary for forgings, in stamping images on coins,
and in ornamental work.
7. Ductility. It is property of a material enabling it to be drawn into wire with the application of a
tensile force. A ductile material commonly used in engineering practice (in order of diminishing
ductility) are mild steel, copper, aluminum, nickel, zinc, tin and lead.
8. Malleability: It is a special case of ductility which permits materials to be rolled or hammered
into thin sheets. A malleable material should be plastic but it is not essential to be so strong.
9. Toughness. It is the property of a material to resist fracture due to high impact loads like
hammer blows.
10. Resilience. It is property of a material to absorb energy and to resist shock and impact loads.
This property is essential for spring materials.
 Explain Ferrous metals and Nonferrous metals characteristics, types and
U1_Q.4. 4
applications.
 Metals: Metals are elemental substances. Metals are composed of elements which readily give
up electrons to provide a metallic bond and electrical conductivity.

1. Ferrous metals: The metals which contain iron as their main constituent are called ferrous
metals.
 Classification of Ferrous Materials: ferrous materials are classified into two Groups:
a) Steel : Steel generally contains between 0.05 and 2.0% weight carbon
b) Cast iron: The cast irons generally contain between 2.0 and 4.5% weight carbon.
 Characteristics of Ferrous Metals
a) High Strength
b) Conductivity
c) Magnetic
d) Corrosion
 Applications of Ferrous Metals
a) Construction: Structural steel is widely used in the construction
b) Transportation: Ferrous metals are used in the automotive, aerospace etc
c) Machinery and Equipment: They are used in the manufacturing of machinery, tools.
d) Energy Generation: Ferrous metals are used in power
2. Non-ferrous metals: The metals which contain a metal other than iron as their main
constituents are called nonferrous metals.
 Types of Nonferrous metals
a) Aluminium
b) Copper
c) Nickel
d) Bronze
e) Brass
 Characteristics of Nonferrous Metals
 a) Corrosion Resistance
b) Lightweight
c) Excellent Conductivity
 Applications of Nonferrous Metals
a) Electrical and Electronics
b) Aerospace
c) Transportation
d) Packaging
e) Plumbing
U1_Q.5. Discuss
5 Composite materials characteristics, types and applications.
Composite Material: A composite material is formed by combining two or more distinct components
with different properties to create a new material with enhanced or unique characteristics.
 Properties/characteristics of composite materials
 Strength
 Mechanical Properties
 Corrosion Resistance
 Design Flexibility
 Thermal and Electrical Conductivity
 Types of Composite Materials
1. Fiber-Reinforced Composites: These composites consist of a matrix material (usually a
polymer, metal, or ceramic) reinforced with fibers. The most common types are
A. Fiber-Reinforced Polymers (FRP): These include carbon fiber composites and fiber glass
composites.

B. B. Metal Matrix Composites (MMC): These composites use metals as the matrix material,
often reinforced with ceramic or carbon fibers.

2. Particulate Composites: These composites consist of a matrix material with dispersed

particles (e.g., ceramics, polymers, or metals). Example: concrete (cement matrix with
sand and gravel particles) .
 3. Laminated Composites: These composites are built up from multiple layers (laminae) of
materials, each with different properties.

4. Hybrid Composites: These composites combine two or more different types of

reinforcement or matrix materials to achieve specific performance characteristics.

 APPLICATIONS OF COMPOSITE MATERIALS:

 Automotive
 Construction
 Aerospace
 Marine
 Energy
 Medical
 Electronics etc
U1_Q.6. Explain
6 Ceramics characteristics, types and applications in detail.
Engineering ceramics is the science and technology of creating objects from inorganic,
nonmetallic materials. This is done either by the action of heat or at lower temperature. It is also
known as advanced ceramics or technical ceramics.
 Characteristics of Engineering Ceramics
 High Hardness
 Chemical Stability
 Temperature Resistance
 Electrical Resistance
 Wear Resistance
 Low Friction
 Types of Engineering Ceramics
1. Alumina (Al₂O₃): Strong, electrically resistant, and thermally conductive. Purity ranges
from 95% to 99.9%.
2. Silicon Carbide (SiC): Extremely hard, stable at high temperatures, and resistant to
thermal shock. Used in abrasives, aerospace, and automotive parts.
3. Silicon Nitride (Si₃N₄): Strong, thermally stable, and corrosion-resistant. Ideal for high-
stress, high-temperature uses like bearings and cutting tools.
4. Zirconia (ZrO₂): Strong, wear-resistant, and thermally shock-resistant. Available in
partially or fully stabilized forms, suited for various applications.
5. Titanium Diboride (TiB₂): Extremely hard and chemically stable. Used in cutting tools
 and wear-resistant components.
 Applications of Engineering Ceramics
1. Cutting Tools:
2. Electrical Insulators
3. Wear Parts
4. Medical Devices
5. Aerospace Components
6. Thermal Insulation
7. Chemical Industry
8. Electronic & Medical Instruments
U1_Q.7. What are smart materials, and explain their importance?
Definition: Smart or intelligent materials are material that has to respond quickly to
temperature, pressure, electric flow, magnetic flow, light, mechanical, etc. and activate their function
according these changes.
1. Piezoelectric Materials: Generate electricity under mechanical stress or deform under an
electric field. Used in sensors, actuators, and energy harvesters.

2. Shape Memory Alloys (SMAs): Return to their original shape when heated or stimulated.
Applications include medical devices, robotics, and aerospace.
3. Electrostrictive and Magnetostrictive Materials: Change shape when exposed to electric or
magnetic fields. Common in sensors and transducers.
4. Thermoelectric Materials: Convert heat into electricity and vice versa. Used in waste heat
recovery and power generation.
5. Smart Polymers (Hydrogels): Adapt structure in response to temperature, pH, or moisture.
Used in drug delivery, artificial muscles, and tissue engineering.
6. Phase Change Materials (PCMs): Store and release heat during phase changes, ideal for
temperature regulation.
 Applications of Smart Materials and Structures
1. Aerospace
2. Healthcare
3. Electronics.
4. Automotive
5. Robotics
6. Military and Defense
UNIT-2
U2_Q1. Explain the casting process with a neat sketch
Definition: Casting process is a manufacturing process in which molten material is poured into the
casting cavity or mold cavity and allowed to harden or solidify.
List of Components(write here)
1. Pattern Making Creating a Pattern: A pattern is a replica of the final product. It is made of
wood, metal, or plastic and is used to create the mold cavity
2. Mold Making: Mold is a container made from green sand and which has cavity in which
molten metal can poured. Mold box has two halves, the upper halve is called cope and lower
halve is called drag.
 3. Core Making Core Production: Cores are used to create internal cavities in the final product.
Cores are made from sand or other materials and are placed inside the mold before casting

4. Metal Melting and Pouring: The raw material is melted using furnace.
 The molten metal is poured into mold using ladle.
5. Solidification:
 Metal is allowed to cool to room temperature,
 During solidification the metal shrinks and the extra metal required compensate this
shrinkage is obtained from the riser
6. Finishing:
 Undesired part which corresponds to gating system and riser has to be cut from
main casting.
 The casted surface generally is rough and some finishing operation like grinding,
machining, polishing are required.
7. Inspection:
 Before dispatching the casted part has to be checked for desired dimensions. The part
which doesn’t meet expected dimensions has to be scraped.
 Castings are also checked for various undesirable defects
U2_Q2. Discuss CNC Machine components and its application.
CNC machines are automated manufacturing devices controlled by a computer. They
operate based on numerical data inputted into a computer program.

CNC Machine
Components of CNC Machines:
 Machine Control Unit (MCU)
 Motors
 Drive System
 Tool Spindle
 Table or Work bed
 Coolant System
Working Principle of CNC Machines:
 Design the Object: Create a 3D model of the part using CAD software.
 Generate CNC Code: Convert the design into machine-readable instructions using CAM
software.
 Load the Code: Upload the CNC code to the machine's control system.
 Set Up the Machine: Secure the material on the machine table and attach the cutting
tool.
 Start the Machine: The CNC machine follows the code to cut and shape the material
precisely.
 Check the Process: Monitor the machine and check the quality of the finished product.
Applications
 Automotive Industry
 Aerospace Industry
 Medical Industry
 Electronics Industry
 Art and Design
 Furniture Industry
 Prototyping
U2_Q3. What is 3D Printing? Explain the advantages and applications of 3D printing
Definition: 3D printing also known as additive manufacturing. It is a manufacturing process that
creates 3-dimensional objects by adding layers of material on top of each other until the desired
shape is achieved.

 The process starts with a digital model that is created using computer-aided design
(CAD) software or obtained from a 3D scanner.
 The digital model is then converted into a series of thin, two-dimensional slices that can
be used as a blueprint for the 3D printer.
 The 3D printer reads the slice data and creates the object layer by layer, by depositing or
melting the material in a controlled manner.
 This process is repeated until the entire object is created.
 The materials used in 3D printing vary depending on the type of printer and the desired
outcome, but commonly include plastics, metals, ceramics, and composites
 Applications
1. Manufacturing
2. Healthcare
3. Architecture:
4. Education
5. Entertainment
U2_Q4. Explain the working principle of boiler with a sketch.
Definition: Boiler is a heat exchanger and it is use to generate the steam in thermal power plant.
Types :
1. Water Tube Boilers: It is a type of boiler that uses water-filled tubes to generate the steam.
2. Fire Tube Boiler: A fire tube boiler is a type of boiler in which hot gases pass
Simple Vertical (Lamont) Boiler: Lamont boiler is a high pressure water tube boiler which works
on forced circulation system.
 Main Components of Lamont Boiler
1. Air Pre Heater
2. Economizer
3. Super Heater
4. Evaporator
5. Furnace
6. Steam separating drum
7. Circulating pump

Working Principle of Lamont Boiler:

 The feed water from the hot well is stored in the steam separating drum.
 The circulating pump supplies water to the distribution headers which distribute water to
the evaporator tubes.
 The water is heated by the radiation heat of the combustion chamber in the radiant
evaporator.
 The mixture of water and steam coming out from the radiant evaporator, then enters the
convective evaporator.
 The hot flue gases passing over the evaporator tubes transfer a large portion of heat to the
water by convection.
 Thus, water 1s converted into steam and it enters the steam separating rum.
  The steam separated out from the drum enters the superheater tubes where it is
superheated by the hot flue gases passing over them.
 The superheated steam then enters the steam turbine for power generation.
U2_Q5. Explain working principle of Single cylinder Four strokes SI Engine.

Four Stroke Petrol Engine: Fig.2.34 illustrates the various strokes/series of operations which take
place in four stroke petrol (Otto cycle) engine.

Stroke-1: Suction Stroke

Stroke-2: Compression Stroke
Stroke-3: Expansion Stroke
Stroke-4: Exhaust Stroke

Stroke I
Suction Stroke (5-1): During this stroke the piston moves from top dead centre
(T.D.C) to bottom dead centre (B.D.C.); the inlet valve opens and proportionate
Fuel Air Mixture is sucked in the engine cylinder.
Stroke II
Compression Stroke: In this stroke, the piston moves (1—2) towards (T.D.C.) and
compresses the enclosed fuel air mixture The pressure of the mixture rises in the
cylinder. At the end of this stroke the Spark-plug ignites the mixture and
combustion takes. Both the inlet and exhaust valves remain closed during the
Stroke.
Stroke III
Expansion or Working Stroke: When the mixture is ignited by the Spark Plug
combustion takes place and the piston move T.D.C. to B.D.C. and thus the Work is
obtained in this stroke. The expansion of the gases is shown by 3-4. At the end of
 this strpke exhaust valve will be open.
Stroke IV .
Exhaust stroke. The Smoke and Un Burnt fuel particles escape through exhaust
valve to the atmosphere. The piston moves from B.D.C. to T.D.C. and the exhaust
gases are driven out of the engine cylinder; this is also called scavenging. This
operation is represented by the line (1-5) (Fig. 2.35)
U2_Q6. Explain vapor compression refrigeration system.
Definition: Refrigeration is the process of keeping the temperature of a space or substance lower
than the surrounding air.
Vapour Compression Refrigeration (VCR) System: A VCR is a type of refrigeration system
that uses a refrigerant to absorb and remove heat from a space, thereby cooling it. This
system operates based on the principle of the vapor-compression refrigeration cycle,
Diagram

Main Components:
1. Compressor
2. Condenser
3. Capillary tube/Expansion Valve
4. Evaporator
1. Compression: During suction stroke of the compressor, the low-pressure refrigerant vapour
from the evaporator is drawn into the compressor. The vapour Refrigerant is compressed to
a high pressure and temperature.
2. Condensation: The high pressure and high temperature refrigerant vapour cooled in the
condenser therefore heat is removed by circulating water or air. Thus the refrigerant
vapour gets transformed into liquid (Condensation) state.
3. Expansion: After condensation the high pressure liquid refrigerant is passes through an
expansion valve the pressure of the refrigerant is reduced. Then the liquid refrigerant is
goes lowest level.
4. Vaporization: The liquid-vapour mixture of the refrigerant then enters the evaporator or
refrigerated space where the refrigerant absorbs heat from the refrigerated space and
refrigeration is furnished. This lowers the temperature in the freezing compartment. Thus
the cycle is completed. The refrigerant vapours are once again sucked by the compressor
and the cycle repeats.
U2_Q7. What is the difference between a petrol engine and a diesel engine?
SN Petrol Engines Diesel Engines
1 A petrol engine draws a mixture of petrol A diesel engine draws only air during the
 and air during the suction stroke. suction stroke.
2 The carburetor is used in petrol engines The injector is used in diesel engines
3 Spark plug is used to ignite the mixture Spark plugs are not necessary.
Compression ratio approximately from 6 Compression ratio approximately from 15 to
4
to 10. 25.
5 It works on Otto cycle. It works on Diesel cycle.
6 The thermal efficiency is up to about 26%. The thermal efficiency is up to about 40%.
7 Overheating trouble is more Overheating trouble is less
8 The starting of petrol engine is easy The starting of the diesel engine is difficult
The diesel engines are costlier and heavy
9 These are cheaper and lighter in weight.
weight.
10 The running cost is high. The running cost of the diesel engine is low
11 The maintenance cost is less. The maintenance cost is more.
Diesel engines are relatively low-speed
12 Petrol engines are high-speed engines.
engines.
Ex: scooters, motorcycles, cars. These are Ex: buses, trucks, tractors, earth moving
13
also used in airplanes. machines, etc.
UNIT-3
U3_Q.1. Explain the working principle of nuclear power plant with diagram.
Definition: A nuclear reactor used to produce energy by splitting Nucleus (nuclear fission),
releasing heat. This heat produces steam, which drives turbines to generate electricity.
Nuclear fission  Heat  Steam  Mechanical Energy  Electrical Energy
Layout

Components of a Nuclear Reactor: The essential components of a nuclear reactor are as follows:
1. Reactor core
2. Fuel rod
3. Moderator
4. Coolants
5. Control Rods
6. Boiler
7. Turbine
8. Generator
Working Principle:
 A nuclear reactor works on the principle of controlled nuclear fission. The fuel, such as
 uranium, undergoes fission, releasing a large amount of heat and neutrons.
 A moderator slows down these neutrons to sustain the chain reaction, while a reflector
improves efficiency by redirecting escaping neutrons back into the core.
 The heat generated is absorbed by a coolant, which transfers it to produce steam that drives
turbines to generate electricity.
 Control rods regulate the reaction by absorbing excess neutrons, ensuring safety and stability.
 Shielding prevents radiation from escaping, and the reactor vessel contains the entire system
under high pressure
U3_Q.2. Explain the working principle of Steam power plant with diagram.
Definition: Nuclear power plants are used to generate electrical energy by convert steam into
mechanical energy and then electrical energy.
Layout:

Steam Power Plant Circuits:

1. Coal circuit
2. Ash circuit
3. Ash and gas circuit
4. Feed water circuit
5. Steam flow circuit
6. Cooling water circuit.
The Components:
1. Coal & Coal handling plant.
2. Ash & Ash handling plant.
3. Boiler
4. Turbine
5. Generator
6. Cooling Towers
7. Draught system
Working Principle:
 Coal is brought to the plant and sent to the furnace using the coal handling system.
 The coal burns in the furnace, producing heat to convert water into steam in the boiler.
 The steam is superheated and sent to a turbine, where it expands and rotates the turbine
blades to produce power.
 After doing work in the turbine, the steam passes to the condenser, which cools it down,
converting it back into water.
 Cooling water from sources like rivers, lakes, or cooling towers is used in the condenser to
maintain low pressure.
  Some steam from the turbine is sent to heaters for preheating water.
 Air from the atmosphere is preheated using exhaust gases before it enters the furnace for
combustion.
 Exhaust gases are cleaned using dust collectors and released into the atmosphere through a
chimney.
U3_Q.3. Discuss components of diesel engine power plant with a sketch.
Definition: Diesel power plants are used to generate electrical energy by convert Heat Energy into
mechanical energy and then electrical energy.

Components
1. Engine
2. Fuel system
3. Air filter
4. Exhaust system
5. Cooling system
6. Lubricating system
7. Starting system
Working of a Diesel Power Plant (Simplified):
 Air from the atmosphere is drawn into the compressor, where it is compressed and sent to
the diesel engine after being cleaned in an air filter to remove dust and dirt.
 Fuel oil from the storage tank is filtered to remove impurities and injected into the engine
using a fuel pump and injector.
 Inside the engine, the compressed air mixes with the fuel, and the high pressure and
temperature cause the mixture to ignite, leading to combustion.
 The heat energy produced during combustion drives the engine's piston, converting thermal
energy into mechanical energy.
 This mechanical energy is transferred to a generator, which converts it into electrical energy
for use.
U3_Q.4. Explain the working principle of hydro Electric power plant with a sketch.
Definition: A hydroelectric power plant is a type of power station that generates electricity
by using the kinetic energy of falling or flowing water to turn turbines, which in turn drive
generators that produce electricity
Components:
1. Catchment area
2. Reservoir
3. Dam
4. Spillways
5. Surge tanks
6. Draft tubes
7. Powerhouse
Working
 Water from a river or stream is stored in a reservoir created by building a dam. This reservoir
ensures a steady supply of water for power generation.
 The dam raises the water level to create hydraulic head, providing the necessary pressure for
the operation of turbines.
 Water from the reservoir is released through large pipes called penstocks, directing it toward
the turbines.
 The high-pressure water flows through the turbines, causing them to rotate. These turbines
are connected to generators, which convert mechanical energy into electrical energy.
 After driving the turbines, the water is discharged back into the river downstream,
completing the cycle.
U3_Q.5. Explain Gear Drives and their applications.
Definition: A gear drive is a mechanical system that uses gears to transfer motion and torque
between machine parts. It helps control the speed, direction, and force in various machines and
devices.
GEAR DRIVES
 Gear drives for motion and power transmission
from one shaft to another.
 They consist of a driving gear (on the input shaft)
and a driven gear (on the output shaft).
 Power transmission from the power source to the
load takes place through the meshing of the gear
teeth.
 Due to the many available designs, they can work in a number of orientations and
applications.
 A gear drive can handle higher loads compared to a chain drive but is only suitable for short
distances, as the gears need to be in direct contact with each other.
 Using multiple gears in a gear train makes it possible to change the gear ratio, rotational
speed, torque and direction as needed. Too many gears in a single system will, however,
reduce mechanical efficiency.
Applications of Gear Drives:
1. Automobiles
2. Industrial Machinery
3. Pumps and Compressors
4. Electric Motors
5. Wind Turbines
6. Bicycles
 7. Aerospace
8. Construction Equipment
Advantages
o Gears have high efficiency and do not slip
o Suitable for high Power transmission applications.
o Gears are sturdy and have long service lives
o Compact setup
Disadvantages
o Not suitable long distance. High vibration and noise
o Increase the weight
o They require lubrication
o Costlier than other drives (chain, belt, etc.)
o Meshing gears require precise alignment
U3_Q.6. Compare and contrast belt drive and chain drive.
Aspect Belt Drive Chain Drive
A belt drive uses a flexible belt placed A chain drive uses a chain and
Definition around pulleys to transfer power sprockets to transfer power between
between two shafts two shafts

Diagram

 Flat Belt  Roller Chain

Types  V-Belt  Block Chain
 Rope Drive  Leaf Chain
Transfers power via friction between Transfers power via sprockets and a
Mechanism
belt and pulleys. chain.
Does Not slip, ensuring consistent
Slip Can slip, causing speed variation.
speed.
Works well for slow to very high
Speed Suitable for moderate to high speeds.
speeds.
Less Durable; prone to wear and More Durable but needs frequent
Durability
stretching. lubrication.
Noise Quiet and smooth operation. Noisy and may cause vibrations.
Low maintenance, occasional tension Requires regular lubrication and
Maintenance
adjustment needed. tensioning.
Applications
U3_Q.7. Explain various configurations of robot manipulator with neat
sketches.
A robot configuration refers to the design and arrangement of a robot's joints, arms, and axes that
determine how it moves and the shape of its workspace. It defines the robot's range of motion,
flexibility, and capabilities. There are six major types of robot configurations:
1. Cartesian
2. Cylindrical
3. Spherical
4. SCARA (Selective Compliance Articulated Robot Arm)
5. Articulated
6. Delta (Parallel)
 Robot
Explanation Common Uses
Configuration
Moves along x, y, and z axes in a box
Cartesian 3D printers
shape.
Rotates around a central axis and Assembly, machine handling,
Cylindrical
moves up/down and in/out. welding
Rotates in a spherical workspace with Die casting, injection molding,
Spherical
two axes. welding
SCARA (Selective
Combines Cartesian and cylindrical
Compliance Assembly, palletizing,
motions with pivot points for precise
Articulated Robot biomedical tasks
movement.
Arm)
Flexible joints (shoulder, elbow, wrist) Assembly, welding, material
Articulated
for multi-axis movements. handling
Uses parallel linkages for fast tool
Delta (Parallel) High-speed pick-and-place tasks
movement.
U3_Q.8. Describe the anatomy of a robot and its applications?
Robot: A robot is a type of automated machine that can execute specific tasks with little or no
human intervention and with speed and precision
Applications of Robotics
1. Manufacturing: Robots handle tasks like welding, painting, assembly, and moving
materials.
2. Healthcare: Surgical robots assist with precision, and robots help in therapy, patient care,
and medication delivery.
3. Agriculture: Robots plant, harvest, and monitor crops, and assist with livestock
management.
4. Space Exploration: Robots explore planets, moons, and asteroids (e.g., Mars rovers).
5. Transportation: Autonomous cars, drones for deliveries, and self-driving buses/trains.
6. Logistics: Robots move goods in warehouses, especially in e-commerce.
7. Energy: Robots inspect and maintain energy systems like pipelines, power plants, and
solar panels.
8. Environmental Clean-up: Robots clean up hazards like oil spills and nuclear waste.
9. Defense: UAVs and drones for surveillance, bomb disposal robots for handling explosives.
10. Entertainment: Robots are used for animatronics in theme parks and movies.
11. Research: Robots assist in scientific research, such as ocean exploration and lab tasks.
12. Aerospace: Robots help in aircraft manufacturing, maintenance, and inspection.

Short Answer Questions

UNIT-1
List the various types of metals used in engineering.
 Ferrous Metals: Steel, Cast Iron
1  Non-Ferrous Metals: Aluminum, Copper, Zinc, Lead
 Alloys: Brass, Bronze, Stainless Steel
What are the important properties of ceramic materials?
 High Hardness
2  Chemical Stability
 Temperature Resistance
 Electrical Resistance
  Wear Resistance
 Low Friction
Define the terms strength and Hardness.
1. Strength. It is the ability of a material to resist the externally applied forces
3 without breaking or yielding.
2. Hardness. Material hardness is the ability of a material to withstand force without
scratching, penetration, and indentation
What are the types of composite materials?
 Fiber reinforced composites
4  Particulate composites
 Laminate composites
 hybrid composites
Define Smart Materials.
Smart or intelligent materials are material that has to respond quickly to
5 temperature, pressure, electric flow, magnetic flow, light, mechanical, etc. and
activate their function according these changes.
List various types of metals.
6  Ferrous Metals: Steel, Cast Iron steel alloy etc.
 Non-Ferrous Metals: Aluminium, Copper, Zinc, Lead etc.
Define composite materials
Composite Material: A composite material is formed by combining two or more
7 distinct components with different properties to create a new material with
enhanced or unique characteristics.
Define Ferrous and Non Ferrous
 Ferrous Metals: Metals that contain iron as main content are called Ferrous
Metals
8 Example: steel, cast iron etc.
 Non-Ferrous Metals: Metals that do not contain iron are called Ferrous Metals
Example : Aluminium, copper, zinc).
UNIT-2
What is casting.
Definition: Casting process is a manufacturing process in which molten material is
1 poured into the casting cavity or mold cavity and allowed to harden or solidify.
(if possible: Draw a small diagram otherwise no need)
What is smart manufacturing?
Smart Manufacturing refers to the use of advanced technology and data analytics to
improve the manufacturing process such as
2 1. IoT (Internet of Things),
2. AI (Artificial Intelligence),
3. ML (Machine Learning), and
4. Robotics
What are the main advantages of CNC machines over conventional machines?
CNC machines offer following compared to conventional machines.
 Greater Precision And Repeatability,
3  Good Quality
 Handle Complex Designs
 Higher Efficiency And Speed
What are the four strokes of an IC engine?
Stroke-1: Suction Stroke
4 Stroke-2: Compression Stroke
Stroke-3: Expansion Stroke
Stroke-4: Exhaust Stroke
5 Difference between SI and CI engines.
 Si Engine Ci Engine
 Uses Spark Ignition  Uses Compression Ignition
 Runs on Petrol  Runs on Diesel
 Has a Carburetor for Air-Fuel Mixing  Has a Fuel Injector
 Generally Higher Speed  Higher Torque Output
What is the purpose of a compressor?
6 in refrigerators, the purpose of a compressor is to circulate the refrigerant and increase
its pressure and temperature,
Difference between Drilling and Boring
Drilling: The process of creating a new hole in a material using a drill bit.
7 Boring: The process of enlarging an existing hole to achieve greater accuracy or a
specific diameter.
Define Hot working and Cold working
1. Hot Working Process: In hot working process, the metal is deformed (changing
8 the shape) above the recrystallization temperature.
2. Cold Working Process: In cold working process, the metal is deformed (changing
the shape) below the recrystallization temperature.
What is combustion in IC Engines?
 Combustion in IC engines is the burning fuel with air in the engine's combustion
9 chamber.
 Which release energy in the form of heat to produce mechanical work
UNIT-3
What are belt drives?
Belt drives are mechanical systems that use flexible belts to transmit power between
1 two rotating shafts.
 Types: Flat Belt, V-Belt , Rope Drive
List the different types of gears.
1. Spur Gear 4. Worm Gear
2 2. Helical Gear 5. Rack and Pinion
3. Bevel Gear
Define robot.
3 Robot: A robot is a type of automated machine that can execute specific tasks with
little or no human intervention and with speed and precision
List the different power transmission systems
4 1. Belt Drives 3. Gear Drives
2. Chain Drives 4. Hydraulic Systems
List the five Components of Steam power plants
1. Coal & Coal handling plant. 4. Generator
5 2. Ash & Ash handling plant. 5. Turbine
3. Boiler 6. Cooling Tower
List the five Components of Nuclear power plants
1. Reactor core 5. Boiler
6 2. Fuel rod 6. Turbine
3. Moderator 7. Generator
4. Control Rod
Define Turbine and Generator
 Turbine: Turbine is a device used to converts Fluid Energy (Steam, Gas, or Water)
8 into Mechanical Energy by Rotating Blades.
 Generator: Generator is a device used to converts Mechanical Energy into
Electrical Energy.