1. What is Design?

 Design is an idea and imagination of an object and process to convert the Idea to virtual
Prototype.

2. What do you understand by engineering Drawing?

 Engineering Drawing is a technical document used to transfer technical information and

define requirements.
 It is a graphical language that communicates ideas and information from one mind to
another.

3. What are the engineering Tolerance’s?

 Engineering tolerance are allowable variations from given dimensions. In other words, its
is the total amount by which a given dimension may vary without affecting product
function.
Tolerance (for Hole = Hole (MMC) – Hole (LMC))
4. Why Tolerance is Required?

 The production of closely mating parts without Tolerances is Economically Unfeasible,

this will decrease the rejection rate and Manufacturing cost. Therefore, Tolerances are
used with part dimensions to facilitate manufactures and reduce cost.

5. What are the types of Tolerance?

 Unilateral Tolerance
 Bi-lateral Tolerance

6. A wire Rope is designated as 6*19 standard Hoisting. What Do the numbers 6*19
represent?

 Number of strands * Number of wires in each strand.

7. What is tolerance Stack up Analysis?

 The Tolerance Stack up Analysis is a Design Tool Used to analyses and optimize. The
product assembly. It calculates the cumulative effects of the part tolerances in assembly.

8. What do you understand by fit?

 The terms fit refers to the permissible clearances between mating parts. The clearance
between mating parts determines the types of fits.
 The fit is defined as the assembly conditions of mating part like hole & shaft.

9. What are the different types of fits, please give example?

 Clearance fit: H7g6 – Piston & Slide valves.

 Interference fit: H7p6 – Bearing Bush
 Transition fit: H7k6 – Shaft key
10. Explain term of Hole “M10 * 1.4 depth 35?
M10: Metric screw of diameter 10 mm
1.4: Pitch of the Thread
35 is Depth of the Hole

11. What is Section, Projection, Isometric and Detailed view?

 Section View: It is used to show the interior construction of part in an engineering

Drawing.
 Projection View: The Projection view represents 3-Dimensional objects in 2-Dimensional
while looking from one side.
 Detailed view: It represents larger view of any section of engineering Drawing.
 Isometric view: Isometric projection represents 3d objects into 2d objects in engineering
Drawings. In this three coordinate Axis appear equally foreshortened and the angle
between any two axes is 1200.

12. What are the different projection method use for engineering Drawings?

 First Angle Projection

 Third Angle Projection

13. What is the symbol of 1st and 3rd angle projection?

14. What is the Difference between 1st and 3rd angle projection?

1st Angle Projection 3rd Angle Projection

In 1 Angle projection part lies in 1st
st
In 3 Angle projection part lies in 3rd
rd

Quadrant. Quadrant.
Therefore, object lies in Between Plane and Therefore, Projection plane is lies in
Observer. between Observer and Object.

15. Why 2nd and 4th angle Projection are not used?

 As per rule of projection; when Horizontal plane is rotated 900 in clock wise direction,
The Top and Front view of an object will overlap and overlapping projection view creates
confusion in Drawing Due to This, we can not use 2nd and 4th Angle projection.

16. What is the least count and how it is calculated?

 It is the smallest Value measured with the measuring Instruments. For example, the least
count for a normal scale is 1mm. Where as for vernier caliper is 0.02mm.
 Least count = value of one Main Scale Division – Total No of Vernier Scale Division.

17. What is the least count for vernier caliper Micrometer and Normal Scale?

 Vernier caliper Least Count = 0.01mm (Digital)

0.02mm (Manual)
 Micrometer Least count = 0.01mm
 Normal Scale least count = 1mm

18. What is the factor of safety (FOS) and how it is calculated?

 Factor of safety describes the load carrying capacity of a beyond the expected or actual
load.
 In other words, Factor of safety represents How much stronger the system is compared
to the intended load
(or)
 The Ratio Maximum stresses to working stress is known as factor of safety.
Factor of safety = Yield stress / Working Stress.
 Factor of Safety is calculated considering the design load Maximum Value.
 The value of Factor of safety is always greater than 1.

19. What is Datum plane?

 A Datum is theoretical exact plane, Axis (or) Point Location that GD&T (or) Dimensional
Tolerances are Referenced to.

20. Why we use Hole Basic system Mostly?

 We produce standard Hole by using Tools like Drilling, Boring, Reaming etc.
  In a hole basis system, the hole is kept as the constant, and the shaft upper and lower
deviation values determine the type of fit. In a hole basis system, the Lower deviation of
the hole will be Zero.

21. What is Shaft base System?

 In the Shaft basis system, the shaft is kept as the constant, and hole upper and lower
deviation values determine the type of fit. In the shaft basis system, the upper deviation
of the shaft will be Zero.

Conclusion

Out of these two bases of limits systems, hole basis system is preferred over shaft basis system
due to from manufacturing perspective it is easy to adjust the shaft dimension by using grinding or
turning operation whereas holes are produced with drilling operations and it becomes
complicated to do any further turning or grinding operations in holes.

22. What is Stress-Strain curve?

 The Stress Strain curve represents the behavior of Material when an external Force is
applied to it.
 This diagram is used by Product design Engineering during Material selection and
Structure design calculation.

23. What is Unilateral Tolerance?

 If the variation from basic size is in one direction, system of tolerance is called Unilateral
Tolerance.
| 5.5+-0.55 |
24. What is Bi-lateral Tolerance?

 If the variation from basic size is in both direction, system of tolerance is called Bi-lateral
Tolerance.
| 5.5+0.55(or)-5.55 |

25. What is the GD & T (Geometric Dimension & Tolerance)

 GD & T is a system used for defining Engineering Tolerances.

 It helps in Conveying Product assembly requirements to manufactures.

26. How many classifications are there in Indian standard system for Fits?

 Clearance fit
 Interference fit
 Transition fit

Clearance fit Interference fit Transition fit

It is Kind of fit in which Shaft In which diameter always less It is a fit in which Close
diameter always less than than shaft diameter Clearance.
Hole diameter (or)
Close interference is
observed
Hole > Shaft Hole < Shaft Hole = Shaft

27. Apply GD &T on Below Sketch?

28. What are the Anatomy or Nomenclature of a following GD & T Annotation?

29. What is Standard Sheet Size for Drawing?

 A4: 210 * 297

 A3: 297 * 420
 A2: 420 * 594
 A1: 594 * 841
 A0: 841 * 1189

30. What is Metal and Non-metal?

 Metal – Metals are class of substances which have high electrical and thermal
conductivity.
 Malleability, Ductility and High reflectivity of light.
Example: - Steel, cast iron, Copper and Aluminum etc.
 Non-Metal – Non-Metal are class of substances which are shaft and have poor thermal
and electrical conductivity Non-Ductile, Non-Malleable.
Examples: - Wood, Glass, Rubber, Leather and Plastic.
31. Why steel is More Elastic than rubber?

 Steel is more elastic than rubber. If an equal stress is applied to both steel and rubber,
The Steel Produces less strain.
 So, the young’s Modulus is Higher for steel than rubber. The object which has high
young’s modulus is more elastic.

32. What is difference between ductile and Brittle Material.

 Ductility: -
 Ductile Material can be draw into wires.
 Ductile Material show large deformation.
 Ductility is affected by temperature.
Example: - Aluminum, Copper, Gold and Silver etc.
 Brittle: -
 Brittle Material Break / Crack when drawn
 Brittle Material show negligible deformation.
 Brittle Material is affected by Stresses.
Example: - Cast iron, Ceramic, Concrete and Glass.
33. What two types of surfaces can be produced by lathe machine.

 Cylindrical surface – If cutting tool Moves Parallel to axis of rotations of workpiece.

 Flat surface – If cutting tool Moves Perpendicular to axis of rotation of workpiece.

34. Difference between Mass and Weight Mass is the amount of Matter in an object.
 Weight – Weight is a measure of how the force of gravity acts upon that Mass.
 Weight is Mass Multiplied by the acceleration of gravity(g).
 Unit of Mass is weight & Unit of weight is N.
35. How much is 1 kg of Newton?

 1kg = 9.81 N

36. What are the type of tolerances?

Tolerance
Dimensional Geometric
Unilateral
Bi-lateral
37. What are types of dimensional tolerance?

 Unilateral tolerance if dimensions of a part is allowed to vary only on one side of basic
size, either below (or) above the basic size.
 Bi-lateral tolerance if dimensions of a part is allowed to vary only on both of basic size.

38. What is single point and multi point tool.

 Single point cutting tools contains only one Main cutting edge in the cutter body.
Example: - turning tool, Shaping Tool and Boring tool etc.
 Multi Point cutting tools contains More than one (even up to hundreds) cutting edges in
the cutter body.
Example: - Drill bit, Milling Cutter and Broaching Etc.

39. What is Poisson’s ratio?

 Poisson’s ration it is ratio of lateral strain to linear strain.

 Lateral strain change in diameter to original diameter.
 Linear strain change is length to original length.

40. What are two alloys of copper?

 Brass (Cu-2n)
 Bronze (Cu-sn)

41. What is full form of CNC, VMC & HMC?

 CNC – Computer Numerical Control.

 VMC – Vertical Machining Centers.
 HMC – Horizontal Machining Centers.

42. What is Dial Gauges are used for?

 Dial Gauges are used to Measure the Flatness and Inclination of objects.
 It is Used to check roundness of round bars.
43. 1 Micron = ______MM?

 1 Micron = 0.001mm

44. What is the heat treatment and its process.

 Heat treatment it is process of heating and cooling of components to change Mechanical

properties of material like Hardness, Ductility or Strength.
Normalizing
Annealing
Hardening
Tempering
Case Hardening
45. What is Fillet and Chamfer?

 Fillet Describes rounded corners of a part.

 Chamfer are sloped or angled edges Purpose to remove sharp Edges.

46. What is stress and strain?

 Stress is internal resisting force developed in a body due to externally applied load per
unit cross sectional area.
 Strain change in dimensions or deformation due to some External Force.

47. How will you define machine?

 An assembly of inter connected components arranged to transmit or modify.

 Force in order to perform useful work.

48. Give me examples of six machine Tools?

 Lathe Machine
 Drilling Machine
 Milling Machine
 Grinding Machine
 Shaper and Planer Machines
 Power saws

49. How to Calculate weight of steel?

Weight of steel = Volume * Density
Volume = Area * Length.
Area = (Based on Shape)
Density = (Based on Material)
Weight = Area * Length * Density
50. What is difference between a circle and Sphere.

 A Circle is a two – dimensional figure.

 A Sphere is a three – dimensional object.
 Area of circle = µr2
 Area of sphere = 4 µr2
51. Area of 2D Shapes Formula

52. What is Tolerance and its types?

 Tolerance It is the permissible variation of abject from its basic size.

 Dimensional tolerance it is used to achieve expected dimensional variation.
 Geometrical tolerance it is used to achieve Expected geometrical variation.

53. What is difference between jig and fixture?

 Jig is used to guide cutting tool as well as to hold workpiece.

 Fixture it is used to hold and locate workpiece but it does not guide cutting tool.

54. What is stress concentration and how to reduce it?

 Stress Concentration is a point in a part where the stress is significantly greater than its
surrounding area.
Reduced by the
Avoid sharp corners.
Use relief notches.
55. What are the three types of plain carbon steel?

 Low carbon (or) Mild steel – 0.3%

 Medium carbon steel – 0.3% to 0.6%
 High carbon steel – 0.6% to 1.5%
56. What is mold.

 Mold it is the cavity of shape of component to be manufacture and into which molten
metal is poured.

57. What is the purpose of electroplating?

 Electroplating is the process of coating surfaces with a metal coating using electricity.
Purpose: -
Corrosion and wear protection
Increasing Surface hardness
Promoting Electrical conductivity
58. Why Second angle and forth angle projection Method is not in Existence?

 Overlapping of the Views.

59. What are the different types of fits?

 Clearance fit
 Interference fit
(Transition fit it is not a practical fit)

60. What are the different types of tolerances?

 Unilateral
 Bi-lateral

61. H8d8 is a _________ Fit?

 Clearance fit(H8d8)

62. H7p6 is a _________ Fit?

 Interference Fit (H7p6)

63. H7m6 is a _________ Fit?

 Transition Fit (H7m6)

64. Value of surface Finish N9 is_____?

 6.3 Microns (N9 Surface Finish)

63. Which standard is followed for GD & T?
 ASME Y 14.5 M 2018

65. Datum is Not required for

a)Concentricity b) Cylindricity c) Run out d) Angularity
 Answer (B. Cylindricity)

66. What is the difference between circularity and runout?

 Circularity is how round a shaft is.

 Runout is a measurement of how close the spinning axis is to it's center line

67. Which geometrical characteristic is used for Mounting surface?

 Flatness

68. In Third angle Method Left Hand Side view is drawn at the _________ side of the
Front view?

 Left

69. Sheet Size of A0 Sheet is ______?

 841 * 1189

70. Draw the symbol of total Runout?

71. Flatness can be checked by using ______?

 Dial Guage

72. A line is parallel to the vertical plane and perpendicular to horizontal plane, Draw Top
View?

 Point

73. What is fake dimension and how it is provided?

74. Steel with 0.4% carbon is

a)Low Carbon steel b)Medium carbon steel c)High Carbon steel

 Answer (b. Medium Carbon steel)

75. When Chromium is added to steel, ______ Property is achieved?

 Corrosion resistance & Hardness

76. Engine valve is produced by _________ Process?

 Forging

77. Cam shaft is produced by ________ Process?

 Forging & Casting

78. Standard Used for GD & T is _____

 ASME Y 14.5 M 2018

79. Following GD&T Characteristic is used for a threaded hole,

a)Parallelism b)Angularity c)Position d) Runout

 Answer (c. position).

80. A Shaft is provided with following GD & T Characteristic

a)Flatness b)Run Out c) Angularity d) Position

 Answer (b. Run Out (All Revolving components))

81. Dashboard of a car is produced by _____ Process?

 Plastic Injection Molding

82. For Mounting of the component following GD&T characteristic is provided:

a)Flatness b) Concentricity c) Circularity d) Run out

 Answer (a. Flatness)

83. Bronze is made up of ________ & __________

 Copper & Tin.

84. Splines are produced by:

a)Boring b) Broaching c) Honing d)Reaming

 Answer (b. Broaching)

85. Following is not a 3D Translator?

a)Iges b) Step c) Dxf d) Stl

 Answer (c. Dxf)

86. Product accuracy of +/- 0.1 mm can be achieved by:

a)Sand Casting b) Forging c) Press Tool d) Investment Casting

 Answer (d. Investment Casting)

 Factors of Selecting Right Material
Requirement’s
1. Strength
2. Accuracy
3. Cost
4. Quantity
5. Complex Geometry
6. Surface Finish
7. Size of the part
8. Machinability
9. Ease of Manufacturing
10. Ease of Modification
11. Weight
12. Life
13. Availabity
14. Working Conditions
15. Atmospheric Conditions

Most Common Used Materials

1. Cast Iron
2. Steel
3. Aluminum
4. Plastic
5. Rubber

1. Cast Iron
Contents:
1. Carbon: 2.5% - 4%
2. Silicon: 1% - 2.5%
3. Manganese: 0.4% - 1%
4. Sulphur: 0.06% - 0.12%
5. Pho spheres: 0.1% - 1%

Cast Iron strengths: -

Ultimate tensile strength (UTS) = 120 – 300 N/mmsq

Compressive Strength = 600 – 750 N/mmsq

Shear Strength = 150 – 225 N/mmsq

Hardness = 150 – 240 BHN

Types of cast iron: -

Grey Cast Iron

Spheroidal Graphite Iron

White Cast Iron

Malleable Cast Iron

 Advantages: -

1. Low Cast
2. Excellent Castability
3. Good Machibility
4. Good Compressive strength
5. Available as per required shape and size
6. Intricate Shapes Possible

Difference Between Cast Iron & Steel

1. Carbon Percentage
2. Type of steel & cast iron
3. Raw Material Availability
4. Strength
5. Surface finish
6. Specific Gravity

2. Steel
Carbon Steel
Alloy Steel
Tool Steel
Stainless Steel

Advantages: -
1. High Strength
2. Better Accuracy
3. Better Finish
4. Thin section can be made

Limitations: -

1. Heavy weight
2. Raw Material As per Market Availability
3. Difficult to cast

3. Aluminum
Advantages: -

1. Light in weight
2. Excellent castability property
3. Excellent Machinibility
4. Excellent Surface Finish
5. Corrosion resistant
 Limitations: -

1. Less Strength
2. Soft material
3. Careful Handling required
4. High Cost

Density of Material

Density of Aluminum – 2.7 g/cm3

Density of Cast Iron – 7.2 g/cm3

Density of Steel – 7.8 g/cm3