Mechanical Engineering

UPSC Mechanical Engineering 2025

All 16 questions from the 2025 Civil Services Mains Mechanical Engineering paper across 2 papers — 800 marks in total. Each question comes with a detailed evaluation rubric, directive word analysis, and model answer points.

16Questions
800Total marks
2Papers
2025Exam year

Paper I

8 questions · 400 marks
Q1
50M Compulsory calculate Mechanics of solids, machine design, materials science

(a) A gripper is shown in the figure. A horizontal force F = 50 N is applied to the handle of the lever at E. The mean diameter of the single square threaded screw at C and E is 25 mm and lead is 5 mm. Determine the clamping force developed at G. The coefficient of static friction is μs = 0·3. (10 marks) (b) The aluminium rod ABC having Young's modulus 70 GPa consisting of two cylindrical portions AB and BC, is to be replaced with a cylindrical steel rod DE with Young's modulus 200 GPa of same overall length. Determine minimum required diameter, d, of the steel rod if its vertical deformation is not to exceed the deformation of aluminium rod under the same load and if the allowable stress in the steel rod is not to exceed 165 MPa. (10 marks) (c) A tank shown in the figure is filled with compressed air under pressure of 8 MPa. A torque of magnitude T = 12 kNm is applied at the end. The tank has an inner diameter of 180 mm and thickness of wall 12 mm. Determine the maximum normal stress and maximum shearing stress in the tank considering the cylinder is thin. (10 marks) (d) With the help of a neat diagram, illustrate the microstructures of various phases of steel and exhibit the presence of the following: (10 marks) (i) Ferrite (ii) Austenite (iii) Cementite (iv) Pearlite (e) A pair of involute profile spur gears in mesh have to give a speed ratio of 2. The pressure angle is 20° and the module is 10 mm. The pinion has 24 teeth and drives the larger gear. If the addenda on pinion and gear wheels are equal to one module, determine: (10 marks) (i) length of path of contact, (ii) contact ratio, and (iii) angle of action of the pinion.

Answer approach & key points

Calculate numerical solutions for all five parts with systematic derivations. For (a)-(c) and (e), show complete free-body diagrams, equilibrium equations, and step-by-step computations. For (d), draw neat microstructure diagrams with proper labelling. Allocate time proportionally: ~15% each for (a), (b), (c), (e) numerical parts and ~25% for (d) diagrams with four microstructures. Conclude each numerical part with final answers in proper units.

  • Part (a): Torque at screw = F × lever arm; thread angle tan(α) = lead/(π×dm); efficiency η = tan(α)/(tan(α+φ)); clamping force = (F×lever arm)×η/(dm/2 × tan(α+φ)) with φ = arctan(μs)
  • Part (b): Equate total deformation δ_al = δ_st; use δ = PL/AE for each segment; check stress constraint σ_st ≤ 165 MPa; solve for minimum d satisfying both conditions
  • Part (c): Hoop stress σ_h = pd/2t; longitudinal stress σ_l = pd/4t; shear stress due to torque τ = Tr/J; principal stresses σ_1,2 = (σ_h+σ_l)/2 ± √[((σ_h-σ_l)/2)²+τ²]; τ_max = (σ_1-σ_2)/2
  • Part (d): Four labelled diagrams showing: (i) BCC ferrite (α-Fe, soft, ductile), (ii) FCC austenite (γ-Fe, high temperature), (iii) orthorhombic cementite (Fe3C, hard, brittle), (iv) lamellar pearlite (alternating ferrite+cementite layers)
  • Part (e): Path of contact = (√(r_a1²-r_b1²) + √(r_a2²-r_b2²) - r_p sinφ)/cosφ; contact ratio = path of contact/(πm cosφ); angle of action = path of contact/r_p1
  • Correct application of thin-walled assumption for (c): d/t = 15 > 10 validates assumption
  • Proper unit conversions: GPa to MPa, mm to m, kNm to Nm throughout all calculations
Q2
50M calculate Mechanics, stress analysis, governor, nanomaterials

(a) (i) A cylinder C weighing 1000 N is supported by two cylinders A and B weighing 500 N each as shown in the figure. Calculate the contact forces at P, Q and R. (10 marks) (ii) The state of plane stress at a critical point in a machine member is as follows: σₓ = 80 MPa tensile, σᵧ = 40 MPa compressive and complementary shear is 25 MPa. The yield strength of the material is 250 MPa. Determine the factor of safety with respect to the yield strength using: (10 marks) (I) maximum shear criterion, and (II) maximum distortion energy criterion. (b) In a Proell governor with open arms, the mass of each ball is 7 kg and the mass of the sleeve (central load) is 140 kg. The length of each arm is 180 mm and the length of extension of lower arms to which the balls are attached is 90 mm. The distance of pivots of the arms from axis of rotation is 25 mm and radius of rotation of the balls is 190 mm when the arms are inclined 40° to the axis of rotation. Determine the equilibrium speed for the given configuration. (20 marks) Further, if the frictional effect is included by incorporating a frictional force of 40 N at the sleeve, determine the coefficient of insensitiveness and range of speed when the governor is insensitive. (c) Classify the nanomaterials depending on the number of dimensions in the nano range. Support your answer with the geometry of classified nanomaterials. (10 marks)

Answer approach & key points

Calculate the contact forces in (a)(i) using free-body diagrams and equilibrium equations for three-cylinder system; compute factor of safety in (a)(ii) applying both Tresca and von Mises yield criteria with principal stress transformation. For (b), derive Proell governor equilibrium speed using instantaneous centre method, then incorporate friction to find coefficient of insensitiveness and speed range. For (c), classify nanomaterials by dimensional constraints with schematic geometries. Allocate approximately 20% time to (a)(i), 20% to (a)(ii), 40% to (b), and 20% to (c) based on marks distribution.

  • (a)(i) Contact forces: P = 577.35 N, Q = 577.35 N, R = 1500 N using angle geometry (30° between cylinder centres) and ΣF=0, ΣM=0
  • (a)(ii)(I) Maximum shear criterion: τ_max = (σ₁-σ₂)/2, compare with σ_y/2; FOS = 250/(2×57.02) ≈ 2.19
  • (a)(ii)(II) Distortion energy: σ_eq = √(σ₁²+σ₂²-σ₁σ₂), compare with σ_y; FOS = 250/96.82 ≈ 2.58
  • (b) Proell governor: equilibrium speed N = 60ω/2π where ω² = (Mg + mg/2)(1+tan²α)tanα / [mr(1+k tan²α)]; k = extension/arm length ratio
  • (b) Coefficient of insensitiveness = (ω₂² - ω₁²)/(2ω²) = F_friction/(Mg + mg/2); speed range ΔN = N_max - N_min
  • (c) 0D: quantum dots (spherical, all dimensions nano); 1D: nanotubes/nanowires (one dimension bulk); 2D: graphene/quantum wells (two dimensions bulk); 3D: bulk nanostructured materials (zero dimensions nano)
Q3
50M solve Vibrations, flywheel, beam analysis, heat treatment defects

(a) (i) The recoil mechanism of a gun consists of a critically damped spring-damper system. The maximum permissible recoil distance of the gun is specified as 0·5 m. If the initial recoil velocity of the gun is 10 m/s and the mass of the gun is 500 kg, determine the spring stiffness of the recoil mechanism and the critical damping coefficient of the damper. (10 marks) (ii) A punching press executes 10 holes per minute in a 25 mm thick plate. The diameter of each hole is 20 mm. The punch has a stroke of 60 mm and the punch moves with uniform velocity throughout. A flywheel is attached to the press and the mean speed of the flywheel is 25 m/s. If punching requires 10 N-m of energy per mm² of the sheared area, find the power needed to operate the punching press. Further determine the mass of the flywheel required if the total fluctuation of speed is restricted to 5% of the mean speed. (10 marks) (b) A beam AB under loading is shown in the figure. The rigid bar DEF is welded at a point D. The Young's modulus of the beam material is 200 GPa and its moment of inertia is 20 × 10⁶ mm⁴. (i) Draw shear force diagram. (ii) Draw bending moment diagram. (iii) Find the maximum bending moment and its location. (iv) Find deflection at C. (20 marks) (c) Identify the different types of defects and their causes in a steel article after it is hardened. (10 marks)

Answer approach & key points

Solve each sub-part systematically with clear section headers. For (a)(i)-(ii), apply vibration theory and flywheel energy equations respectively, showing all substitutions. For (b), draw SFD/BMD first, then use Macaulay's method or moment-area for deflection at C—allocate ~40% time here as it carries 20 marks. For (c), enumerate heat treatment defects with metallurgical causes. Conclude each numerical part with units and physical reasonableness checks.

  • (a)(i) Critical damping: uses x_max = (v_0/ω_n)*e^(-1) for critical damping, or solves characteristic equation with ζ=1; finds k = mω_n² and c_c = 2√(mk)
  • (a)(i) Correct values: k ≈ 20,000 N/m (or 20 kN/m), c_c ≈ 6,324 Ns/m (or 6324 kg/s) from x_max = 0.5 m, v_0 = 10 m/s
  • (a)(ii) Energy per hole: E = 10 N·mm/mm² × π×20×25 mm² = 15,708 J; power = (10×15708)/60 = 2,618 W ≈ 2.62 kW
  • (a)(ii) Flywheel mass: uses ΔE = Iω²C_s = ½m(v₂²-v₁²); with C_s=0.05, finds m ≈ 168 kg (or similar based on exact formulation)
  • (b) SFD: shows reactions, constant shear in segments, jump at D due to rigid bar, correct sign convention
  • (b) BMD: linear/parabolic variations, maximum moment location identified (typically near D or under load), values at key points
  • (b) Deflection at C: applies conjugate beam method or Macaulay's integration with boundary conditions; δ_C ≈ 2-5 mm range depending on loading
  • (c) Hardening defects: quenching cracks (thermal gradients), distortion (uneven cooling), retained austenite (insufficient cooling), soft spots (decarburization/uneven heating), oxidation/scaling
Q4
50M solve Kinematics, shaft design, epicyclic gear train, engine balancing

(a) A car is moving in a straight line with a velocity of v = (0·6t² + 2t) m/s for a short duration, where t is in seconds. Take initial time t = 0, s = 0. Find : (i) distance travelled in 4 s, and (ii) acceleration at 4 s. (10 marks) (b) A solid shaft AB rotates at 450 rpm and transmits 20 kW from the motor M to machine tools connected to gears F and G. A power of 8 kW is taken off at gear F and 12 kW is taken off at gear G. The allowable shear stress is 55 MPa. Determine the smallest permissible diameter of the shaft AB. (20 marks) (c) (i) In an epicyclic gear train of the sun and planet type shown in the figure below, the annular gear 'A' meshes internally. The three identical planet wheels 'P' of equal size, mesh with annular gear 'A' and the sun wheel 'S'. The planet wheels are carried by a star shaped spider 'C'. The size of the different toothed wheels are such that the spider 'C' which carries the planet wheels is to make one revolution for every 5 rotations of the spindle carrying the sun wheel 'S', when the gear 'A' is stationary. If the minimum number of teeth on any wheel is 14, determine the number of teeth for all the wheels. Further, if the driving torque on the sun wheel is 200 N-m, determine the fixing torque required to keep the annular gear 'A' stationary. (10 marks) (ii) In a four cylinder symmetrical engine, the intermediate cranks are at 90° and each has a reciprocating mass of 500 kg. The engine is in complete primary balance. The centre distance between intermediate cranks is 600 mm and between extreme cranks is 1800 mm. The lengths of the connecting rods and cranks are 800 mm and 200 mm, respectively. Determine the masses fixed to the extreme cranks along with their relative angular positions. If the engine speed is 150 rpm, find the magnitude of secondary unbalanced forces. (10 marks)

Answer approach & key points

Solve all five sub-parts systematically, allocating time proportionally to marks: ~12 minutes for (a), ~24 minutes for (b), ~12 minutes for (c)(i), and ~12 minutes for (c)(ii). Begin each part with the governing equation, show complete derivation with proper units, and conclude with numerical answers. For (c)(i), draw the epicyclic gear train diagram; for (c)(ii), sketch the crank arrangement and secondary force polygon.

  • Part (a): Integrate v = 0.6t² + 2t to get s = 0.2t³ + t²; evaluate s(4) = 28.8 m; differentiate to get a = 1.2t + 2; evaluate a(4) = 6.8 m/s²
  • Part (b): Calculate torque T = P/(2πN/60) = 424.4 N·m; apply τ_max = 16T/(πd³) with τ_allow = 55 MPa; solve for d = 34.4 mm; round up to 35 mm or next standard size
  • Part (c)(i): Apply epicyclic train equation (N_S - N_C)/(N_A - N_C) = -T_A/T_S with N_A = 0, N_C/N_S = 1/5; derive T_A = T_S + 2T_P; with T_P = 14 minimum, solve T_S = 21, T_A = 49; fixing torque = 200 × (5-1) = 800 N·m
  • Part (c)(ii): Apply primary balance conditions Σmr cosθ = 0 and Σmr sinθ = 0; for symmetrical engine, m₁ = m₄, m₂ = m₃ = 500 kg; solve m₁ = 250 kg at 180° to intermediate cranks; secondary unbalanced force = 2mrω²(λ/2)cos2θ with λ = r/l = 0.25; compute F_sec = 1542 N
  • Units and significant figures: All answers carry proper SI units (m, m/s², mm, N·m, N, kg); intermediate steps retain 3-4 significant figures
Q5
50M Compulsory calculate Manufacturing processes and production engineering

(a) A low carbon steel stock of thickness 25 mm is to be rolled in two stages. In the first stage, the reduction is to be from 25 mm to 15 mm and in the second stage from 15 mm to 5 mm. Determine the minimum diameter of the rolls for the two stages if the maximum angle of bite is 35° for the first stage and 25° for the second stage. Also, calculate the required coefficient of friction in both the stages. 10 marks (b) In an arc welding process of steel with a potential of 15 volt, current of 150 Amp and travel speed is 5 mm/sec, the cross-sectional area of joint is observed as 15 mm². If heat required to melt the steel is 10 J/mm³ and heat transfer efficiency is 0·75, then calculate the melting efficiency. 10 marks (c) In an automobile manufacturing industry the demand for a specific part was 250 in April, 100 in May and 200 in June. The forecast for April was 150. Calculate the forecast for the month of July with a smoothing constant of 0·25 and using first order exponential smoothing. 10 marks (d) Five different products are manufactured in a mixed model production line. The time required for each task is given below: Each product requires a set of tasks. Calculate the total number of work stations for this mixed-model assembly line, if the cycle time is 15 seconds. 10 marks (e) For the given dimensions of mated parts, determine the values of allowance, hole tolerance and shaft tolerance using the basic hole system. Hole : 57·50 mm Shaft : 57·47 mm 57·52 mm 57·45 mm 10 marks

Answer approach & key points

Calculate each sub-part systematically, allocating approximately 20% time to each part given equal 10-mark weighting. Begin with rolling mechanics (a), proceed through welding efficiency (b), exponential smoothing (c), assembly line balancing (d), and tolerance analysis (e). Present derivations first, then substitute values, and conclude with boxed final answers for each sub-part.

  • Part (a): Apply bite angle formula α = cos⁻¹(1 - Δh/D) to find D₁ = 68.5 mm and D₂ = 131.4 mm; coefficient of friction μ = tan(α) giving μ₁ = 0.70 and μ₂ = 0.47
  • Part (b): Calculate heat supplied H_s = η_t × V × I / v = 337.5 J/mm; heat required H_r = 150 J/mm; melting efficiency η_m = H_r/H_s = 44.4%
  • Part (c): Apply exponential smoothing F_t = F_{t-1} + α(A_{t-1} - F_{t-1}) sequentially: May=175, June=156.25, July=167.19 (or 167.2)
  • Part (d): Determine total task time per product, compute weighted average or sum of task times, then apply N = Σt_i / C to find minimum workstations (typically 4-5 stations depending on task precedence)
  • Part (e): Identify hole limits (57.50, 57.52) and shaft limits (57.45, 57.47); calculate allowance = 0.03 mm, hole tolerance = 0.02 mm, shaft tolerance = 0.02 mm; classify as transition fit
  • All parts: Show SI units consistently, state assumptions clearly, and verify answers against physical feasibility (e.g., roll diameter > reduction, efficiency < 100%)
Q6
50M calculate Advanced manufacturing processes and plant layout

(a) (i) If the power source characteristic in a Metal Inert Arc welding process is V_P = 38 - I/60, and the arc characteristic is V_a = 3L_a + 27, where V_P and V_a is voltage, I is current and L_a is arc length in mm. Calculate the change in power of the arc if the arc length is changed from 1 mm to 3 mm. If the maximum current capacity of the power source is 300 Amps, then determine the maximum arc length that can be sustained. 10 marks (ii) An electro-discharge machining process is used for cutting a 6 mm deep cavity in a high carbon steel workpiece using the following: (I) Copper-tungsten electrode, and (II) Copper electrode. Assuming the wear ratio for copper-tungsten electrode as 9 : 1 and for copper electrode as 3 : 1, determine the required spindle movement for cutting this cavity. 10 marks (b) (i) A long hole having 15 mm diameter and 125 mm depth is required to be drilled in high carbon steel using electro-chemical machining process. Calculate the time required to drill this hole if the supplied current magnitude is 45 Amp and electrolyte used is 15% NaCl. Consider that the valency of iron is 2, atomic weight of iron is 56 and density of steel is 7·8 gm/cm³. 10 marks (ii) An electro-chemical machining process is used for machining of Nimonic 75 alloy. The composition (% by weight) of Nimonic 75 alloy is given here: | Ni | Cr | Fe | Si | Mn | Cu | Ti | |----|----|----|----|----|----|----| | 72·5 | 19·5 | 5·0 | 1·0 | 1·0 | 0·6 | 0·4 | Consider the following data: | Metal | Gram atomic weight | Valency of dissolution | Density gm/cm³ | |-------|-------------------|------------------------|----------------| | Nickel | 58·71 | 2/3 | 8·90 | | Chromium | 51·99 | 2/3/6 | 7·19 | | Iron | 55·85 | 2/3 | 7·86 | | Silicon | 28·09 | 4 | 2·33 | | Manganese | 54·94 | 2/4/6/7 | 7·43 | | Copper | 63·57 | 1/2 | 8·96 | | Titanium | 47·9 | 3/4 | 4·51 | Using the lowest valency of dissolution for each element, determine the material removal rate, when a current of 1050 Amp is applied. 10 marks (c) With the help of a line diagram, explain the different types of flow patterns used in plant layouts. What are the conditions to be satisfied by an ideal flow pattern ? 10 marks

Answer approach & key points

Calculate numerical solutions for all five sub-parts with systematic derivations. For (a)(i)-(ii), solve MIG arc power equations and EDM spindle movement using wear ratios. For (b)(i)-(ii), apply Faraday's laws of electrolysis for ECM material removal rates. For (c), sketch line diagrams showing straight-line, L-shaped, U-shaped, S-shaped, and circular flow patterns with ideal conditions. Allocate approximately 15 minutes per 10-mark sub-part, ensuring unit consistency throughout.

  • (a)(i) Equate V_P = V_a to find operating point; calculate power P = VI at L_a = 1 mm and 3 mm; find ΔP = P_3 - P_1; determine max L_a at I = 300 A using V_P(300) = V_a(L_a,max)
  • (a)(ii) Apply EDM wear ratio definition: tool wear/workpiece removal; for 6 mm depth cavity, spindle movement = depth × (1 + wear ratio) for each electrode material
  • (b)(i) Apply Faraday's law: MRR = (A × I)/(ρ × Z × F); calculate volume of hole = π×(1.5)²×12.5 cm³; time = volume/MRR using given NaCl electrolyte data
  • (b)(ii) Calculate equivalent gram equivalent weight for Nimonic 75 alloy using lowest valencies; apply weighted average based on composition percentages; MRR_total = (I × Σ(w_i × A_i/Z_i))/(F × ρ_eff)
  • (c) Draw line diagrams for: straight-line (product layout), L-shaped (medium variety), U-shaped (cellular manufacturing), S-shaped (process layout), circular (robotic/FMS); state ideal conditions: minimum backtracking, shortest distance, smooth flow, flexibility, safety
Q7
50M calculate Orthogonal machining, inventory management, break-even analysis

(a) HSS cutting tool with 9° rake angle, the following data were observed in an orthogonal machining process of medium carbon steel workpiece: Feed rate = 0·25 mm/rev Cutting speed = 250 m/min Depth of cut = 1·5 mm Chip thickness ratio = 0·30 Vertical cutting force = 1100 N Horizontal cutting force = 600 N Calculate the: (i) Shear force along the shear plane (ii) Normal force on the shear plane (iii) Friction force along the rake surface (iv) Normal force along the rake surface (v) Friction angle (vi) Work done in shear (vii) Work done in friction (20 marks) (b) The annual requirement of an item is 2400 units. Each item costs the company ₹ 6. The manufacturer offers a discount of 5% if 500 or more quantities are purchased. If the ordering cost is ₹ 32 per order and inventory cost is 16%, determine whether it is advisable to accept the discount. (20 marks) (c) The following cost-related data has been collected from a company: | Cost Element | Variable Cost | Fixed Cost | | Direct material | 32·8 | – | | Direct labour | 28·4 | – | | Factory overheads | 12·6 | 1,89,900 | | Distribution overheads | 4·1 | 58,400 | | General administrative overheads | 1·1 | 66,700 | | Budgeted sales | – | 18,50,000 | Determine the following: (i) Break even sales volume (ii) Profit at the budgeted sales volume (iii) Profit if the actual sales I. Drop by 10%, and II. Increase by 5% from budgeted sales. (10 marks)

Answer approach & key points

Calculate all numerical sub-parts systematically, allocating approximately 40% time to part (a) given its 7 sub-questions and 20 marks, 35% to part (b) for EOQ with discount analysis, and 25% to part (c) for break-even analysis. Begin each part with stated assumptions and formulae, show complete step-wise calculations with units, and conclude with clear final answers for each sub-part.

  • Part (a): Shear angle φ = arctan(r·cosα/(1-r·sinα)) = arctan(0.3×cos9°/(1-0.3×sin9°)) ≈ 16.7°; then F_s = F_c·cosφ - F_t·sinφ and F_n = F_c·sinφ + F_t·cosφ
  • Part (a): Friction force F = F_c·sinα + F_t·cosα and normal force N = F_c·cosα - F_t·sinα; friction angle β = arctan(F/N)
  • Part (a): Work done in shear = F_s × V_s where V_s = V·cosα/cos(φ-α); work done in friction = F × V_c where V_c = V·sinφ/cos(φ-α)
  • Part (b): EOQ = √(2×D×S/(I×C)) = √(2×2400×32)/(0.16×6) ≈ 400 units; compare total costs at EOQ vs discount lot size 500
  • Part (b): Total cost = DC + (D/Q)S + (Q/2)IC; verify if 5% discount on ₹5.70 with Q=500 beats EOQ total cost at ₹6
  • Part (c): Contribution margin ratio = (Sales - Variable cost)/Sales; BEP sales = Fixed cost/CM ratio
  • Part (c): Profit calculations at budgeted, 90% and 105% sales using P = (Sales × CM ratio) - Fixed costs
  • Part (c): Total variable cost per unit = ₹79.0; total fixed costs = ₹3,15,000; CM ratio = (18,50,000 - (2400×79))/18,50,000
Q8
50M calculate NC machine languages, quality control charts, manufacturing cost analysis

(a) What are the various computer languages used for NC machines? Explain the merits and limitations of each language. (10 marks) (b) A small manufacturing unit produces bolts and the weight of each bolt is measured. The target weight for a bolt is 60 grams. A sample of 5 bolts is taken every day for 30 days. The weight (in grams) for first 5 days is given below: Calculate the control limits for the X̄ (X-bar) chart. The constant A₂ for a sample size of 5 is 0·577. (20 marks) (c) A certain component can be manufactured either by welding or by forging process. The factory has an order for 5,00,000 units. The costs involved for both methods of manufacturing are as follows: | Cost | Welding | Forging | | Fixed cost | ₹ 15,000 | ₹ 94,000 | | Variable cost/unit | ₹ 5 | ₹ 4·25 | (i) Which is the most economical method of manufacturing the component? Draw the indicative graph also for BEP. (ii) What will be the loss if a wrong choice is made? (20 marks)

Answer approach & key points

Calculate requires systematic treatment of all three parts: for (a) enumerate NC languages with comparative merits/limitations; for (b) compute X̄ chart control limits using given A₂ constant with proper statistical steps; for (c) determine BEP by equating total costs, compare at 5,00,000 units, sketch cost-revenue graph, and quantify wrong-choice loss. Allocate roughly 20% time to (a), 35% to (b), and 45% to (c) given mark distribution.

  • Part (a): APT, G-code/M-code, and conversational languages identified with specific merits (APT for complex 3D contours, G-code universal compatibility, conversational for shop-floor ease) and limitations (APT needs post-processor, G-code low-level tedious, conversational limited flexibility)
  • Part (b): Correct calculation of grand mean X̿ from sample data, average range R̄ computation, UCL = X̿ + A₂R̄ and LCL = X̿ - A₂R̄ with A₂ = 0.577 applied, final control limits numerically stated
  • Part (c)(i): BEP calculation by equating total costs: 15000 + 5Q = 94000 + 4.25Q yielding BEP = 1,12,000 units; welding economical below BEP, forging above; at 5,00,000 units forging is cheaper
  • Part (c)(i): Indicative BEP graph with fixed cost lines (horizontal), total cost lines (sloping), intersection at BEP, and 5,00,000 unit point marked showing forging advantage
  • Part (c)(ii): Loss calculation: Cost at wrong choice (welding at 5,00,000) minus cost at correct choice (forging at 5,00,000) = ₹2,65,00,000 - ₹2,21,50,000 = ₹43,50,000 loss

Paper II

8 questions · 400 marks
Q1
50M Compulsory calculate Thermodynamics, Heat Transfer and Fluid Mechanics

(a) A lump of ice with a mass of 1·5 kg at an initial temperature of 260 K melts at the pressure of 1 bar as a result of heat transfer from the environment. After some time, the resulting water attains the temperature of environment, 293 K. Calculate the entropy production associated with this process. The latent heat of fusion of ice is 334 kJ/kg, the specific heat of ice and water are 2·07 kJ/kg-K and 4·2 kJ/kg-K, respectively. Assume that ice melts at 273·15 K. (10 marks) (b) Downstream of a normal shock wave, the characteristic Mach number M*_{y} = 0·5 and the stagnation pressure is 2 bar. Determine the following: (i) The Mach number M_{y} downstream of the shock (ii) The stagnation pressure upstream of the shock The fluid is air and γ = 1·4, and R = 0·287 kJ/kg-K. Normal shock table and Isentropic flow table provided at the end, may be used. (10 marks) (c) Show, in the form of a table, how the following parameters change (increase/decrease/remain constant) across a normal shock wave: Static pressure, Static temperature, Stagnation pressure, Stagnation temperature, Stagnation density, Mach number, Entropy and Stagnation enthalpy (10 marks) (d) At a certain instant of time, the temperature across a large wall of thickness 50 cm is given as T(x) = 90 - 80x + 16x² + 32x³ - 25x⁴ where x is in metres and measured from the left face of the wall as shown in the figure below and T is in °C. If the area of the wall is 10 m² and there is no generation of heat in the wall, compute the following: (i) The rate of heat entering and leaving the wall (ii) The rate of heat energy stored in the wall (iii) The rate of temperature change with time at x = 0 and x = 0·5 m (10 marks) (e) A 120 W electric bulb has a filament temperature of 3005 °C. Assuming the filament to be black, calculate (i) the diameter of the filament wire if the length is 250 mm and (ii) the efficiency of the bulb based on visible radiation if the visible radiation lies in the wavelength range from 0·4 μm to 0·75 μm. Assume Stefan-Boltzmann constant (σ) as 5.67×10⁻⁸ W/m²-K⁴. The black body radiation functions are given in the table: | λT(μm-K) | f₀→λ | |----------|------| | 1300 | 0.004317 | | 1400 | 0.007791 | | 2400 | 0.140266 | | 2500 | 0.161366 | (10 marks)

Answer approach & key points

Calculate systematically across all five parts: (a) entropy production for ice melting requires three-stage entropy analysis; (b) normal shock uses characteristic Mach number relations and tables; (c) tabular comparison of shock parameters; (d) transient heat conduction with polynomial temperature profile; (e) blackbody radiation with fractional emission. Allocate approximately 20% time to each part, ensuring all numerical working is shown with proper units and sign conventions.

  • (a) Three-stage entropy calculation: ice warming 260→273.15 K, melting at 273.15 K, water warming 273.15→293 K; entropy production = ΔS_system + ΔS_surroundings with Q/T_boundary for surroundings
  • (b)(i) Characteristic Mach number M* = √[(γ+1)/2 * M²/(1+(γ-1)M²/2)] inverted to find M_y = 0.534 downstream
  • (b)(ii) Stagnation pressure ratio across shock from normal shock tables: p_0x/p_0y = 1.113, giving p_0x = 2.226 bar upstream
  • (c) Tabular comparison: static pressure ↑, static temperature ↑, stagnation pressure ↓, stagnation temperature →, stagnation density ↓, Mach number ↓, entropy ↑, stagnation enthalpy →
  • (d) Heat rates using Fourier's law at x=0 and x=0.5 m: q = -kA(dT/dx); energy storage from ∂T/∂t = α(∂²T/∂x²) with no generation
  • (e)(i) Stefan-Boltzmann law Q = σAT⁴ with T = 3278 K to find filament diameter d = 0.457 mm
  • (e)(ii) Blackbody radiation function interpolation: f(0.4μm) and f(0.75μm) at λT values, visible efficiency η = (f_0.75 - f_0.4) × 100 = 6.53%
  • Consistent units throughout: kJ/kg-K for specific heats, bar for pressure, μm-K for λT products, W/m²-K⁴ for σ
Q2
50M calculate Thermodynamics, Turbomachinery and Convective Heat Transfer

(a) (i) A reversible power cycle engine is used to drive a reversible heat pump. The power cycle takes in Q₁ heat units at temperature T₁ and rejects heat Q₂ at temperature T₂. The heat pump abstracts heat Q₄ from the sink at temperature T₄ and discharges heat Q₃ at temperature T₃. Develop an expression for the ratio Q₄/Q₁ in terms of the four temperatures T₁, T₂, T₃ and T₄. (10 marks) (ii) Argon gas expands adiabatically in a turbine from 2 MPa, 1000 °C to 350 kPa. The mass flow rate of argon is 0·5 kg/s and the turbine develops power at the rate of 120 kW. Determine the following: (1) The temperature of argon at the turbine exit (2) The irreversibility rate (3) The second law efficiency Neglect kinetic and potential energy effects and take T₀ = 20 °C and P₀ = 1 atm. Take molecular weight of argon as 40 kg/kmol and γ = 1·67. (T₀ and P₀ are the environment temperature and pressure, respectively) (10 marks) (b) Compressed air is transported in an industrial pipeline of 50 mm internal diameter. The stagnation conditions at the inlet are P₀ = 10 bar and T₀ = 400 K. The average Fanning friction factor f̄ = 0·002. If the Mach number changes from 3 at the entry to 1 at the exit, determine the following: (i) The length of the pipe (ii) The velocity at the exit (iii) The change in the stagnation temperature (iv) The change in the stagnation pressure (v) The change in the entropy (vi) The mass flow rate Assume the flow to be adiabatic. For air, take γ = 1·4 and R = 287 J/kg-K. Isentropic flow table and Fanno flow table attached at the end, may be used. (20 marks) (c) A thin flat plate, that is 0·2 m×0·2 m on a side, is oriented parallel to an atmospheric air stream having a velocity of 40 m/s. The air is at a temperature of T∞ = 20 °C, while the plate is maintained at Ts = 120 °C. The air flows over the top and bottom surfaces of the plate, and measurement of the drag force reveals a value of 0·075 N. What is the rate of heat transfer from both sides of the plate to the air? (Assume ρair = 0·995 kg/m³, νair = 20·92×10⁻⁶ m²/s, Prair = 0·7, kair = 30×10⁻³ W/m-K) (10 marks)

Answer approach & key points

Calculate and derive expressions for all nine sub-parts systematically, allocating approximately 20% time to (a)(i) reversible cycle derivation, 20% to (a)(ii) argon turbine analysis, 45% to (b) Fanno flow calculations using attached tables, and 15% to (c) Reynolds analogy application. Begin each part with governing equations, substitute given data with proper unit conversions, and conclude with numerical answers and physical interpretation.

  • (a)(i) Derivation: COP_heat_pump = Q₃/W = T₃/(T₃-T₄), η_power_cycle = W/Q₁ = 1-T₂/T₁, combine to get Q₄/Q₁ = (T₁-T₂)(T₃-T₄)/(T₁(T₃-T₄)) with algebraic manipulation for Q₄ = Q₃ - W
  • (a)(ii) Argon turbine: T₂ = T₁(P₂/P₁)^((γ-1)/γ) = 1273×(0.35/2)^0.402 = 773 K; actual work from power = 120/0.5 = 240 kJ/kg; actual T₂ = 1273 - 240/0.312 = 503 K; irreversibility = T₀(s₂-s₁) - q = 293×0.312×ln(773/503) = 38.6 kJ/kg; η_II = (h₁-h₂_actual)/(h₁-h₂_isentropic)
  • (b) Fanno flow: Use tables at M₁=3, M₂=1 to find 4fL*/D = 0.522; L = 0.522×0.05/(4×0.002) = 3.26 m; V_exit = a* = √(γRT*) = 347 m/s; T₀ constant (adiabatic) so ΔT₀=0; P₀₂/P₀₁ from tables = 0.408; Δs = Rln(P₀₁/P₀₂) = 287×ln(2.45) = 258 J/kg-K; ṁ = ρ*A*a*
  • (c) Reynolds analogy: St = Cf/2 = h/(ρCpU); from drag F_D = 2×(1/2)ρU²×Cf×A, find Cf = 0.075/(0.995×1600×0.08) = 0.000588; h = St×ρCpU = (Cf/2)×ρCpU = 0.000294×0.995×1005×40 = 11.7 W/m²K; Q = 2×h×A×(T_s-T_∞) = 2×11.7×0.04×100 = 93.6 W
  • Unit consistency: Convert all temperatures to Kelvin, pressures to consistent units (Pa or kPa), and verify dimensional homogeneity in each equation
  • Table usage in (b): Explicitly state Fanno flow parameter values extracted from tables (e.g., P/P*, T/T*, P₀/P₀* at M=3 and M=1) and show interpolation if needed
  • Second law analysis: Clearly distinguish between isentropic, actual, and dead states for exergy and irreversibility calculations in (a)(ii)
  • Physical verification: Check that results satisfy thermodynamic constraints (e.g., entropy generation ≥ 0, Mach number trends in Fanno flow, heat transfer direction in (c))
Q3
50M calculate Heat transfer and thermodynamics

(a) A long cylindrical rod of radius 10 cm consists of a nuclear reacting material (k = 0·5 W/m-K) generating 24000 W/m³ uniformly throughout its volume. The rod is encapsulated within another cylinder whose outer radius is 20 cm and that has a thermal conductivity of 4 W/m-K. The outer surface is surrounded by a fluid at 100 °C, and the convection coefficient between the surface and the fluid is 20 W/m²-K. Find the temperatures of the interface between the two cylinders, at the outer surface and the maximum temperature under steady-state condition. (20 marks) (b) A centrifugal compressor is to be designed for an industrial application handling air. The inlet stagnation conditions are P₀₁ = 1·1 bar and T₀₁ = 295 K. The air enters the eye of the impeller axially, without any prewhirl. The axial velocity is uniform throughout the eye and is equal to 143 m/s. The eye tip and root diameters are 0·30 m and 0·15 m, respectively. Calculate the mass flow rate of air. The overall diameter of the impeller is 0·50 m. The power input factor is 1·04 and the slip factor is 0·9. The rotational speed of the compressor is 290 revolutions/second. The isentropic efficiency of the compressor (based on total head) is 0·78. The radial velocity at the impeller tip is 143 m/s. Assume that 'half the total losses' occurs in the impeller. Determine the pressure ratio and the power required to drive the compressor. Also, determine the axial depth of the impeller channels at the periphery of the impeller. Draw the T-s diagram showing the variations of both static and stagnation pressures and temperatures in the impeller and the diffuser. For air, γ = 1·4, Cp = 1·005 kJ/kg-K. (20 marks) (c) The velocity and temperature profiles for laminar flow in a tube of radius r0 = 10 mm have the form at a particular axial location u(r) = 0·1(1 - r²/r0²) T(r) = 344·8 + 75 r²/r0² - 18·8 r⁴/r0⁴ with units of m/s and K, respectively. Determine the corresponding value of the mean (or bulk) temperature Tm at this axial position. (10 marks)

Answer approach & key points

Calculate systematically across all three sub-parts: for (a) apply cylindrical heat conduction with internal heat generation and composite wall resistance; for (b) solve centrifugal compressor thermodynamics with velocity triangles, slip factor, and efficiency corrections; for (c) integrate velocity-weighted temperature for bulk mean temperature. Allocate approximately 35% time to part (a), 45% to part (b) due to its multi-step complexity and diagram requirement, and 20% to part (c). Present derivations with clear boundary condition statements and conclude each part with physically verified numerical answers.

  • Part (a): Apply heat conduction equation in cylindrical coordinates with uniform heat generation; use thermal resistance network for composite cylinder with convection at outer surface; identify maximum temperature at centerline (r=0)
  • Part (a): Calculate interface temperature T₁, outer surface temperature T₂, and T_max using continuity of heat flux and temperature at r=10 cm interface
  • Part (b): Calculate mass flow rate using continuity equation with variable annulus area at impeller eye; determine blade tip speed U₂ = πND₂
  • Part (b): Apply slip factor and power input factor to find actual work input; use isentropic efficiency to find pressure ratio; determine impeller channel depth from radial velocity and through-flow area
  • Part (b): Draw complete T-s diagram showing: stagnation and static states at impeller inlet, impeller outlet (with losses), diffuser outlet; label pressure rise and temperature rise correctly
  • Part (c): Apply definition of bulk mean temperature T_m = (∫ρuC_p T dA)/(ṁC_p) = (∫₀^r₀ uT r dr)/(∫₀^r₀ u r dr) for axisymmetric flow
  • Part (c): Perform integration of polynomial terms u(r) = 0.1(1-r²/r₀²) and T(r) = 344.8 + 75r²/r₀² - 18.8r⁴/r₀⁴ to obtain numerical T_m
Q4
50M calculate Heat exchangers and gas turbine cycles

(a) A shell and tube type condenser is employed in a steam power plant to handle 35000 kg/h of dry and saturated steam at 50 °C. The cooling water enters the condenser at 15 °C and leaves at 25 °C. The tubes are of 22·5 mm inside diameter and 25 mm outside diameter. The water flows through the tubes at an average velocity of 2 m/s. The heat transfer coefficient on steam side is 5001 W/m²-K. Calculate the following : (i) The mass flow rate of water (in kg/s) (ii) The heat transfer surface area (based on U₀) (iii) The number of tubes required for water flow (iv) The number of tube passes in condenser if the length of each tube pass should not be more than 2·5 m Assume that condensate coming out from the condenser is saturated water and resistance of tube wall is negligible. For waterside heat transfer coefficient, use the correlation Nu = 0·023 Re⁰·⁸ Pr⁰·⁴. Take latent heat of steam as 2374 kJ/kg. The properties of water at mean bulk temperature of 20 °C are as follows : Pr = 6·98 ρ = 998·9 kg/m³ Cₚ = 4·180 kJ/kg-K ν = 1·0006 × 10⁻⁶ m²/s kƒ = 0·59859 W/m-K Assume fully developed flow through tubes and a single shell is used. (20 marks) (b) A stationary gas turbine plant operates on a Brayton cycle and delivers 20 MW to an electric generator. The maximum temperature is 1200 K and the minimum temperature is 290 K. The minimum pressure is 95 kPa and the maximum pressure is 380 kPa. If the isentropic efficiencies of the turbine and compressor are 0·85 and 0·8, respectively, find— (i) the mass flow rate of air to the compressor; (ii) the volume flow rate of air to the compressor; (iii) the fraction of turbine work output needed to drive the compressor; (iv) the cycle efficiency. If a regenerator of 75% effectiveness is added to the plant, what would be the changes in the cycle efficiency and net work output? Assume Cp and Cv for air as 1·005 kJ/kg-K and 0·718 kJ/kg-K, respectively. (20 marks) (c) The heat transfer rate due to free convection from a vertical surface, 1 m high and 0·6 m wide, to quiescent air that is 20 K colder than the surface is known. What is the ratio of the heat transfer rate for that situation to the rate corresponding to a vertical surface, 0·6 m high and 1 m wide, when the quiescent air is 20 K warmer than the surface? Neglect heat transfer by radiation and any influence of temperature on the relevant thermophysical properties of air. The correlation between Nusselt number and Rayleigh number is given as NūL = 0·10 RaL^0·25. (10 marks)

Answer approach & key points

Calculate all numerical sub-parts systematically: spend ~40% time on part (a) condenser calculations (mass flow, LMTD, overall U, tube count, passes), ~35% on part (b) gas turbine cycle with regeneration analysis, and ~25% on part (c) free convection scaling. Begin each part with stated assumptions, show formulae with substituted values, and present final answers with proper units. Include T-s diagrams for (b) and note physical implications.

  • Part (a)(i): Water mass flow rate = 9.92 kg/s from energy balance Q = m_steam × h_fg = m_water × Cp × ΔT
  • Part (a)(ii): Overall U₀ = 1/(1/h₀ + r₀/rᵢ × 1/hᵢ) with hᵢ from Dittus-Boelter correlation; A₀ = Q/(U₀ × LMTD) where LMTD = 14.43°C
  • Part (a)(iii)-(iv): Tube count from continuity equation; tube passes determined from length constraint L_total/(N_tubes × L_max_pass)
  • Part (b): Compressor and turbine work with isentropic efficiencies; T₂ = 430.9 K, T₄ = 766.3 K; mass flow from W_net = 20 MW
  • Part (b) with regenerator: Effectiveness ε = 0.75 gives T₅ = T₂ + ε(T₄-T₂); revised efficiency and unchanged work output
  • Part (c): Heat transfer ratio = (L₁/L₂)^0.25 × (W₁/W₂) = (1/0.6)^0.25 × (0.6/1) = 0.6 × 1.136 = 0.682 for cold vs hot surface orientation
  • All parts: Proper unit conversions (kg/h to kg/s, kW to W), significant figures, and physical reasonableness checks
Q5
50M Compulsory derive IC engines, boilers, chimney draught, refrigerants

(a) With the help of P-θ (pressure-crank angle) diagram, compare the knock in SI and CI engines. Explain that "the factors which tend to prevent knock in SI engines in fact promote knock in CI engines". (10 marks) (b) Describe the phenomenon of 'blowby losses'. What are the factors that increase the blowby losses? What are the effects of increased blowby losses on the engine performance? (10 marks) (c) What are the advantages and disadvantages of supercritical pressure boilers as compared to that of subcritical boilers? Also, draw the Rankine cycle (T-s diagram) for a steam power plant employing supercritical boiler with single stage of reheating. (10 marks) (d) Derive the expression as given below for draught h in mm of water column being created by a chimney of height H metre: h = 353H[1/T_a - ((m_a + 1)/m_a)(1/T_g)] where m_a is mass of air supplied per kg of fuel, and T_a and T_g are ambient air and hot gas temperatures in Kelvin, respectively. (10 marks) (e) What is the chemical name of R134a? Is R134a an ecofriendly refrigerant? Clarify. (10 marks)

Answer approach & key points

Begin with part (a) by drawing and comparing P-θ diagrams for SI and CI knock, then explain the inverse relationship of factors. For (b), describe blowby mechanism before listing factors and effects. Part (c) requires a balanced comparison of supercritical vs subcritical boilers followed by the T-s diagram with supercritical Rankine cycle and reheat. Part (d) demands rigorous step-by-step derivation of the chimney draught formula using ideal gas assumptions and density relationships. Conclude with (e) by stating R134a's chemical name and critically evaluating its environmental impact through GWP and ODP analysis. Allocate approximately 20% time each to parts (a), (b), (c), (d), and (e) respectively.

  • Part (a): P-θ diagram showing SI knock as sharp pressure spike near TDC vs CI knock as gradual pressure rise; explanation of how high compression ratio, high inlet temperature, and early injection prevent SI knock but promote CI knock
  • Part (b): Definition of blowby as gas leakage past piston rings into crankcase; factors including worn rings, high cylinder pressure, low viscosity oil, poor honing; effects on power loss, oil contamination, increased blowby gas handling requirement
  • Part (c): Advantages of supercritical boilers (higher efficiency ~45%, no drum, reduced fuel consumption, lower emissions) vs disadvantages (high capital cost, materials stress, water treatment criticality); T-s diagram showing supercritical heating, expansion, reheat, condensation with correct slopes and critical point marked
  • Part (d): Derivation starting from hydrostatic pressure balance, ideal gas law for air and flue gas, density substitution ρ = P/RT, pressure difference ΔP = H(ρ_a - ρ_g)g, conversion to mm of water using ρ_w, final algebraic manipulation to given formula
  • Part (e): Chemical name 1,1,1,2-tetrafluoroethane (CF3CH2F); evaluation as eco-friendly regarding zero ODP but high GWP of 1430 over 100 years, comparison with R12 and R22, mention of Kigali Amendment implications for India
  • Part (d) numerical: Correct handling of temperature in Kelvin, proper unit conversion from Pa to mm of water (1 mm H2O = 9.81 Pa), recognition that 353 = 353 K·mm/Pa or equivalent constant derivation
Q6
50M calculate Dual cycle, regenerative steam cycle, absorption refrigeration

(a) A single-cylinder, two-stroke, high-speed diesel engine working on 'dual cycle' has a compression ratio of 15 : 1. The engine takes in atmospheric air at 1 bar and 27 °C. The maximum temperature in the cylinder is 1312 K. The cutoff ratio is 1·093. The engine has a bore of 200 mm and stroke length of 250 mm. The engine speed is 3000 r.p.m. Calculate the following: (i) The cycle efficiency (ii) The net work output per unit mass of air (iii) The power output (iv) The mean effective pressure (v) The ratio of heat added in the constant-pressure process to that in the constant-volume process Draw the P-V and T-s diagrams of the cycle. For air, γ = 1·4, R = 0·287 kJ/kg-K. (20 marks) (b) An ideal regenerative steam power cycle operates so that steam enters the turbine at 30 bar and 350 °C, and exhausts at 0·1 bar. A single open feedwater heater is employed which operates at 5 bar. Compute the thermal efficiency of the cycle. The steam properties at 30 bar and 350 °C are h = 3115·3 kJ/kg and s = 6·7427 kJ/kg-K. Use Steam tables given at the end to get other properties. (20 marks) (c) Why is vapour absorption refrigeration system considered to be a better option in comparison to vapour compression refrigeration system for large capacity refrigeration and air-conditioning plants? (10 marks)

Answer approach & key points

Calculate all numerical sub-parts systematically: spend ~40% time on part (a) dual cycle (20 marks) covering all five parameters and diagrams; ~35% on part (b) regenerative cycle (20 marks) with steam table interpolation and feedwater heater analysis; ~25% on part (c) theory (10 marks) comparing absorption vs compression systems. Present derivations with clear state-point labelling on P-V and T-s diagrams for (a), and T-s diagram with extraction point for (b).

  • Part (a): Correct T2 = 300 × 15^0.4 = 886.3 K; T3 = 1312 K; ρ = 1.093 gives T4 = 1434 K; T5 from isentropic expansion; efficiency = 1 - (T5-T1)/[(T3-T2)+γ(T4-T3)]
  • Part (a): Net work = cv(T3-T2) + cp(T4-T3) - cv(T5-T1); power = W_net × ṁ × (N/60) for two-stroke; mep = W_net/(V1-V2)
  • Part (a): P-V diagram showing 1-2 isentropic compression, 2-3 constant volume heat addition, 3-4 constant pressure heat addition, 4-5 isentropic expansion, 5-1 constant volume heat rejection; T-s diagram with corresponding slopes
  • Part (b): State 1 at 30 bar, 350°C (h1=3115.3, s1=6.7427); s2=s1 at 5 bar gives x2 and h2; h3 at 5 bar saturated liquid; pump work to 30 bar; h6 from turbine at 0.1 bar with s6=s1
  • Part (b): Extraction fraction y = (h3-h5)/(h2-h5); thermal efficiency = [(h1-h2)+(1-y)(h2-h6)]/[(h1-h3)] or equivalent energy balance
  • Part (c): Absorption system uses low-grade heat (waste heat, solar, biomass) vs high-grade work; no CFC/HCFC refrigerants; silent operation; suitable for large tonnage (Indian railways, NHPC power station cooling)
  • Part (c): COP comparison: COP_absorption = COP_Carnot × η_heatengine vs COP_compression; practical limitations (crystallization, part-load efficiency) mentioned for balance
  • All parts: Proper use of steam table data, unit consistency (kJ/kg, kPa, K), and clear identification of state points with numerical values
Q7
50M calculate Thermodynamics and IC Engines

(a) A two-stage turbine receives steam at 50 bar and 350 °C. At 1·5 bar, the high-pressure stage exhausts and 12000 kg of steam per hour is taken at this stage for process heating purposes. The remainder steam is reheated to 250 °C at 1·5 bar and then expanded through the low-pressure turbine to a condensate pressure of 0·05 bar. The power output from the turbine unit is to be 3750 kW. The isentropic efficiency of high-pressure stage is 0·84 and that of the low-pressure stage is 0·81. Calculate the rate of steam being generated per hour by the boiler. Steam properties : 50 bar, 350 °C : h = 3068·4 kJ/kg, s = 6·4492 kJ/kg-K 1·5 bar, 250 °C : h = 2972·65 kJ/kg, s = 7·8709 kJ/kg-K Use Steam tables given at the end to get other properties. (20 marks) (b) (i) What is meant by effective temperature? List and explain briefly the factors which affect optimum effective temperature in air-conditioning. (10 marks) (ii) Explain psychrometric process of adiabatic mixing of two air streams. (10 marks) (c) Why is it necessary to cool IC engines? What are the disadvantages of overcooling an IC engine? (10 marks)

Answer approach & key points

Calculate the steam generation rate for part (a) by applying steady-flow energy equations across both turbine stages, accounting for extraction, reheating, and isentropic efficiencies. For parts (b) and (c), explain effective temperature factors and adiabatic mixing with psychrometric charts, then discuss IC engine cooling necessities and overcooling disadvantages. Allocate approximately 40% time to (a), 30% to (b), and 30% to (c) based on mark distribution.

  • Part (a): Determine isentropic enthalpy at 1.5 bar from s1 = 6.4492 kJ/kg-K using steam tables; find actual h2 using η_HP = 0.84
  • Part (a): Calculate mass flow split: 12000 kg/h extracted, remainder (ṁ-12000) goes to reheating and LP turbine
  • Part (a): Apply energy balance: Power output = ṁ_HP×(h1-h2) + ṁ_LP×(h3-h4_actual) = 3750 kW; solve for total ṁ
  • Part (b)(i): Define effective temperature as index of thermal comfort combining dry-bulb, humidity, and air motion; list factors (clothing, activity, age, sex, climate acclimatization, economic status)
  • Part (b)(ii): Explain adiabatic mixing on psychrometric chart: two states mix along straight line; mass and energy balances give final state; show mixing ratio and enthalpy equations
  • Part (c): Necessity of cooling—prevent thermal stresses, maintain lubricant properties, avoid material failure, control NOx emissions; disadvantages of overcooling—reduced thermal efficiency, increased friction, poor combustion, corrosion, increased fuel consumption
  • Correct use of steam table interpolations for wet region at 0.05 bar and superheated region at 1.5 bar
  • Final answer for (a): steam generation rate in kg/h with proper unit conversion and significant figures
Q8
50M calculate Refrigeration and Nozzle Flow

(a) The following data refers to a single-stage vapour compression refrigeration system : Refrigerant = R134a Condenser temperature = 35 °C Evaporator temperature = – 10 °C Compressor motor speed = 2800 r.p.m. Clearance ratio = 0·03 Swept volume = 269·4 cm³ Expansion index = 1·12 Compression isentropic efficiency = 75% Condensate subcooling in condenser = 5 °C Draw P-h diagram and determine the following : (i) The capacity of the plant in TR (ii) The power required in kW (iii) The COP (iv) The heat rejection to condenser (v) The second law efficiency The properties of R134a are given in the table : | T (°C) | P (bar) | Specific volume of saturated vapour v_g (m³/kg) | Enthalpy (kJ/kg) h_f | h_g | Entropy (kJ/kg-K) s_f | s_g | |--------|---------|-----------------------------------------------|----------------------|-----|----------------------|-----| | – 10 | 2·014 | 0·0994 | 186·7 | 392·4 | 0·9512 | 1·733 | | 35 | 8·870 | — | 249·1 | 417·6 | 1·1680 | 1·715 | Assume specific heat of liquid and vapour at 8·87 bar as 1·458 kJ/kg-K and 1·1 kJ/kg-K, respectively. The refrigerant at entry to compressor is in dry saturated state. (20 marks) (b) (i) What are the important properties of lubricants used in IC engines? Discuss their significance. (10 marks) (ii) What are the advantages and disadvantages of the Indirect Injection (IDI) swirl chamber over the open-type Direct Injection (DI) combustion chamber in CI engines? (10 marks) (c) Calculate the critical pressure and throat area per unit mass flow rate of a convergent-divergent nozzle, expanding steam from 10 bar and dry saturated, down to atmospheric pressure of 1 bar. Assume that the inlet velocity is negligible and that the expansion is isentropic. Use Steam tables given at the end to get the steam data. The value of isentropic expansion index may be taken as 1·135. (10 marks)

Answer approach & key points

Calculate systematically across all three parts, allocating time proportional to marks: ~40% for part (a) refrigeration cycle with P-h diagram and five performance parameters, ~30% for part (b) descriptive IC engine lubrication and combustion chamber comparison, and ~30% for part (c) nozzle critical pressure and throat area derivation. Begin each part with stated assumptions, show all thermodynamic property lookups and interpolation, and conclude with clearly boxed final answers with units.

  • Part (a): Correct P-h diagram with 5 process points (1: dry saturated at -10°C, 2: after compression, 3: saturated liquid at 35°C, 4: after subcooling to 30°C, 5: after expansion); account for isentropic efficiency, clearance ratio for actual mass flow, and expansion index for re-expansion work
  • Part (a): Mass flow rate calculation using clearance ratio and swept volume with volumetric efficiency; refrigerating effect using h1 - h4 with subcooled liquid enthalpy
  • Part (a): Second law efficiency calculation requires Carnot COP between actual evaporator and condenser temperatures, not the saturation temperatures
  • Part (b)(i): Viscosity index, pour point, flash/fire point, oxidation stability, detergency/dispersancy, and alkalinity with significance for engine wear, cold starting, deposit control, and corrosion prevention
  • Part (b)(ii): IDI swirl chamber advantages (quieter, lower injection pressure, better air utilization at part load) vs disadvantages (higher heat loss, lower thermal efficiency, cold starting problems) compared to open DI chamber
  • Part (c): Critical pressure ratio for steam using γ = 1.135; throat area per unit mass flow using isentropic flow relations with steam table enthalpy values, not ideal gas assumption
  • Part (c): Correct use of steam tables to find h1, h2 (isentropic to throat), and specific volume at throat conditions
  • All parts: Consistent units (bar, kJ/kg, m³/kg, K), proper significant figures, and explicit statement of formulas before substitution

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