Mechanical Engineering 2023 Paper I 50 marks Solve

Paper I — Q3

(a) The coefficient of friction for all contacting surfaces in Figure 3(a) is 0·2. Does the 25 kg force move the block A up, hold…

(a)

The coefficient of friction for all contacting surfaces in Figure 3(a) is 0·2. Does the 25 kg force move the block A up, hold it in equilibrium, or is it too small to prevent A from coming down and B from moving out ? The 25 kg force is exerted at the mid-plane of the block so that we can consider this a coplanar problem. 20 marks

(b)

A plane stress condition exists at a point in a loaded structure. The stresses have the magnitude and directions shown on the stress element of Figure 3(b). Calculate the stress acting on the planes obtained by rotating the element clockwise through an angle of 15°. 20 marks

(c)

Discuss microstructure and mechanical properties of pearlite, bainite and martensite. 10 marks

हिंदी में प्रश्न पढ़ें
(a)

चित्र 3(a) में सभी संपर्कीय सतहों का घर्षण गुणांक 0·2 है । क्या 25 kg का बल, गुटका A को ऊपर की तरफ अग्रसर करेगा, संतुलन में रखेगा, या यह इतना छोटा है कि A को नीचे आने से तथा B को बाहर जाने से नहीं रोक पाएगा ? 25 kg का बल गुटके के मध्य-तल पर लग रहा है जिससे कि हम इस समस्या को समतलीय मान सकते हैं । (20 अंक)

(b)

तलीय प्रतिबल की दशा एक भारित संरचना के एक बिंदु पर मौजूद है । प्रतिबलों का परिमाण तथा दिशाएँ चित्र 3(b) में एक प्रतिबल अंश पर दर्शाया गया है । उस तल पर प्रतिबल को परिकलित कीजिए जो कि इस अंश को 15° के कोण द्वारा घड़ी की दिशा में घुमाकर प्राप्त किया गया हो । (20 अंक)

(c)

पर्लाइट, बेनाइट तथा मार्टेंसाइट की सूक्ष्म-संरचना तथा यांत्रिक गुणों की विवेचना कीजिए । (10 अंक)

Q3 of the 2023 UPSC Mains Mechanical Engineering Paper I, as printed
The question as printed in the 2023 Mechanical Engineering paper

The figure this question refers to, in words

The question paper is a scan and the diagram did not survive as text. This is the figure as read from the original page — every component, value and label — so the question can be worked from the text below.

(a) A mechanical system consisting of a block A and a wedge B. On the left is a vertical hatched wall, and at the bottom is a horizontal hatched floor. Block A rests against the vertical wall on its left vertical side. Block A has a horizontal top surface of width 0.6 m (measured from the vertical wall to its right vertical face). The bottom surface of block A is inclined at an angle of 15 degrees to the horizontal, sloping upwards from left to right, and extends from the vertical wall to its right vertical face. The mass of block A is labelled as 100 kg. Below block A is wedge B, which rests on the horizontal floor. Wedge B has a horizontal base of length 0.6 m, a vertical left face, a vertical right face, and an inclined top surface at 15 degrees to the horizontal in contact with the inclined bottom surface of block A. The mass of wedge B is labelled as 50 kg. A horizontal force of 25 kg is applied to the right vertical face of wedge B, directed toward the left. The angle of 15 degrees to the horizontal is indicated to the right of the inclined plane.

(b) A rectangular 2D plane stress element labeled Figure 3(b) subjected to normal and shear stresses:

  • Normal stresses: Tensile stress P2 = 20 N/mm^2 acting vertically outwards from the top and bottom faces (upward on top face, downward on bottom face). Compressive stress P1 = 80 N/mm^2 acting horizontally inwards onto the left and right faces (pointing right into the left face, pointing left into the right face).
  • Shear stresses of magnitude q = 30 N/mm^2: pointing left along the top horizontal edge, pointing right along the bottom horizontal edge, pointing upward along the left vertical edge, and pointing downward along the right vertical edge.

Model answer

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(a) Equilibrium of block A and wedge B with friction

Data: θ = 15°, μ = 0.2 on all contact surfaces, W_A = 100 kgf, W_B = 50 kgf, and a 25 kgf force pushing B to the left. The wall is on the left of A, and B's top face rises to the right, so the reaction N of B on A is normal to the incline and points up and to the left. Let H be the wall reaction on A and R the floor reaction on B. The test is to find the force F needed to start A upward and the force needed to stop A sliding down, and to see where 25 kgf lies.

Case 1: impending motion of A up and B left. Friction on A from B acts down the incline, wall friction on A acts down, and floor friction on B acts to the right.

For A: x: H = N sinθ + μN cosθ = N(sinθ + μ cosθ) y: N cosθ = W_A + μN sinθ + μH Substituting H: N[(1 − μ²)cosθ − 2μ sinθ] = W_A, so N = 100/(0.96 × 0.9659 − 0.4 × 0.2588) = 121.4 kgf H = 121.4 × (0.2588 + 0.2 × 0.9659) = 54.9 kgf

For B (vertical): R = W_B + N(cosθ − μ sinθ) = 50 + 121.4 × 0.9136 = 161.0 kgf For B (horizontal): F_up = H + μR = 54.9 + 0.2 × 161.0 = 87.1 kgf

Since 25 kgf is less than 87.1 kgf, the force cannot push A up.

Case 2: impending motion of A down and B right. All friction directions reverse.

For A: N[(1 − μ²)cosθ + 2μ sinθ] = W_A, so N = 100/(0.96 × 0.9659 + 0.4 × 0.2588) = 97.0 kgf H = N(sinθ − μ cosθ) = 97.0 × 0.0656 = 6.37 kgf For B: R = 50 + 97.0 × (0.9659 + 0.0518) = 148.7 kgf, so the maximum floor friction is μR = 29.7 kgf.

The push of A on B towards the right is only H = 6.37 kgf, which is less than 29.7 kgf. Even with no applied force, B cannot slide out, and the system is self-locking. The balance F = H − μR = −23.4 kgf is negative, meaning no leftward force is required to stop A coming down.

Conclusion: the required force lies between 0 (strictly, a negative value) and 87.1 kgf, and 25 kgf is inside this range. The 25 kg force holds the block A in equilibrium; it neither moves A up nor is it too small.

Diagram: Block and wedge FBD

(b) Stresses on planes rotated clockwise by 15°

Take x to the right and y upward. From the element: σ_x = −80 N/mm² (compressive), σ_y = +20 N/mm² (tensile). The shear on the top face acts to the left and on the right face downward, so τ_xy = −30 N/mm². A clockwise rotation of 15° gives θ = −15°, so 2θ = −30°, cos 2θ = 0.8660 and sin 2θ = −0.5.

Transformation equations: σ_x′ = (σ_x + σ_y)/2 + (σ_x − σ_y)/2 cos 2θ + τ_xy sin 2θ = −30 + (−50)(0.8660) + (−30)(−0.5) = −58.30 N/mm²

σ_y′ = (σ_x + σ_y)/2 − (σ_x − σ_y)/2 cos 2θ − τ_xy sin 2θ = −30 + 43.30 − 15 = −1.70 N/mm²

τ_x′y′ = −(σ_x − σ_y)/2 sin 2θ + τ_xy cos 2θ = −25 − 25.98 = −50.98 N/mm²

So the rotated element carries 58.30 N/mm² compression on the x′ face, 1.70 N/mm² compression on the y′ face, and a shear stress of 50.98 N/mm² in the negative sense.

Check: σ_x′ + σ_y′ = −60 N/mm² = σ_x + σ_y. The Mohr circle has centre −30 and radius √(50² + 30²) = 58.31 N/mm²; the point (−58.30, −50.98) lies at distance √(28.30² + 50.98²) = 58.31 N/mm² from the centre, so it is on the circle.

(c) Microstructure and properties of pearlite, bainite and martensite

Pearlite is a lamellar eutectoid of alternating ferrite and cementite (Fe₃C) plates, formed by diffusion-controlled decomposition of austenite at about 550–727°C. Fine pearlite, formed at lower temperature, has smaller interlamellar spacing and so higher strength and hardness. Pearlite has moderate strength (UTS about 600–900 MPa), hardness about 15–30 HRC, good ductility and good machinability.

Bainite is a non-lamellar aggregate of ferrite and fine carbides, formed isothermally at about 250–550°C. Upper bainite (about 400–550°C) has carbides between ferrite laths; lower bainite (about 250–400°C) has fine carbides inside the laths. Bainite gives a better strength–toughness combination than pearlite at equal hardness, and lower bainite is stronger and tougher than upper bainite. Hardness is about 40–55 HRC.

Martensite forms by diffusionless shear of austenite on rapid quenching below the Ms temperature. It is a body-centred tetragonal supersaturated solution of carbon in iron, lath-type in low-carbon steels and plate-type (twinned) in high-carbon steels. It is the hardest and strongest of the three (up to about 65 HRC) but brittle, with high residual stress and cracking tendency, so tempering is needed to restore toughness.

How this answer will be evaluated

What earns full marks: Complete and correct analysis with clear diagrams and reasoning for all parts.

Evaluation rubric

Each sub-part is marked on its own, against the marks and word limit printed on the paper.

  1. (a) Decide whether the 25 kg force moves block A up, holds it in equilibrium, or is too small, with friction 0.2 everywhere. 20 marks

    analyse— intro → causes → effects → stakeholders/linkages → way forward

    Must cover

    • Free-body diagrams with correct friction directions
    • Impending up: N 121.4, H 54.9, R 161.0, F 87.1 kgf
    • Impending down: H 6.37 < mu R 29.7, self-locking
    • 25 kgf lies inside the range, so equilibrium

    Loses marks

    • Ignoring wall friction on A.

    Earns more

    • Marks for FBDs, both limiting cases and the conclusion.

    Extra mark

    • Noting the self-locking of the wedge.
  2. (b) Calculate the stresses on planes rotated clockwise through 15° from the given element. 20 marks

    calculate— given → formula → substitution → result with units → interpretation

    Must cover

    • sigma_x -80, sigma_y +20, tau_xy -30
    • theta = -15 degrees
    • sigma_x' -58.30, sigma_y' -1.70
    • tau_x'y' -50.98 N/mm2

    Loses marks

    • Taking anticlockwise rotation.

    Earns more

    • Marks for sign conventions, transformation equations and results.

    Extra mark

    • Mohr circle or invariant check.
  3. (c) Discuss the microstructure and mechanical properties of pearlite, bainite and martensite. 10 marks

    discuss— intro → 3-4 dimensions → example → balanced close

    Must cover

    • Pearlite: lamellar ferrite plus cementite
    • Bainite: ferrite and fine carbides, 250-550 C
    • Martensite: BCT, diffusionless, hardest
    • Properties and hardness compared

    Loses marks

    • Describing only one constituent in detail.

    Earns more

    • Marks for structure and properties of each phase.

    Extra mark

    • Effect of tempering on martensite.
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