Tamil Nadu HSE Second Year Basic Mechanical Engineering study plan

Define stress, strain and Young's modulus, and solve at least 15 numericals on elongation, load and factor of safety for loaded bars.

Resolve at least 10 coplanar force systems into components, then apply the parallelogram law and Lami's theorem to find unknown tensions.

Calculate the resultant, moment and couple of coplanar force systems for 8 lever and beam cases, stating the equilibrium conditions used.

Interpret a tensile test stress-strain curve, mark proportional limit, elastic limit, yield point, ultimate stress and breaking stress, and compute percentage elongation.

Sequence the sand-casting process from pattern to shake-out, and label cope, drag, sprue, riser, core, gate and parting line on a two-box mould drawn from memory.

Classify at least 8 casting defects (blowhole, shrinkage cavity, misrun, cold shut, hot tear, sand inclusion) by cause and remedy.

Compare arc, gas, TIG and MIG welding on heat source, electrode or filler, shielding, typical application, one advantage and one limitation.

Distinguish hot working from cold working, and describe rolling, forging, extrusion and wire drawing with one industrial product example for each.

Classify ferrous and non-ferrous engineering materials, and match hardness, toughness, ductility, malleability and brittleness to the test that measures each.

Compare grey, white, malleable and spheroidal graphite cast iron on carbon content, microstructure, two properties and two typical uses.

Explain annealing, normalising, hardening, tempering and case hardening by stating purpose, procedure, one property change and one application.

Write the approximate composition and one application of brass, bronze, duralumin, stainless steel and a bearing alloy.

Draft dimensioned drawings of 5 simple machine parts using correct BIS line types, lettering heights, arrowheads and dimension placement.

Construct front, top and side views of 6 simple objects (stepped shaft, V-block, bracket, bush) in first-angle projection.

Convert 4 given orthographic view sets into isometric sketches and justify each visible edge.

Draw one full sectional and one half-sectional view of a hexagonal nut and a simple pulley, with hatching at 45 degrees.

Label the parts of a centre lathe, and match turning, facing, taper turning, thread cutting, knurling and boring to the tool, feed and work holding used.

Explain the working of radial drilling, shaping, up-milling versus down-milling, and surface grinding, each with a labelled sketch.

Select HSS, carbide, ceramic or diamond for 5 stated cutting conditions (speed, hardness, continuity of cut) and justify each selection.

Compute cutting speed, feed rate and machining time for 6 turning and drilling numericals using the standard formulae.

State the zeroth, first and second laws of thermodynamics, and calculate work done and heat transfer for isothermal, adiabatic and constant-pressure processes in 6 problems.

Define sensible heat, latent heat, dryness fraction and degree of superheat, and solve 5 problems using steam properties.

Compare four-stroke and two-stroke petrol and diesel engines on valve or port operation, power strokes per revolution, lubrication, efficiency and application.

Compute compression ratio, swept volume and indicated power from given bore, stroke and speed, and draw the valve timing diagrams for petrol and diesel engines.

Apply Pascal's law and the continuity equation to 6 pipe and pressure problems, and state the assumptions behind Bernoulli's equation.

Calculate discharge through a venturi meter and a small orifice for 5 data sets, and classify centrifugal, reciprocating, Pelton, Francis and Kaplan machines by head and discharge range.

Compute the least count of a vernier caliper, micrometer and vernier height gauge, and record 8 readings applying zero-error correction.

Assign limit dimensions and identify clearance, transition or interference fit for 5 given hole-shaft pairs on a hole-basis system.

Select personal protective equipment for 6 workshop situations, and match fire classes A, B, C and D to the correct extinguisher and isolation action.

Distinguish preventive, breakdown and predictive maintenance with one plant example and one cost consequence for each.

List two hazards and two controls each for marking, filing, hacksawing, drilling and tapping at the bench.

Re-solve the 20 most frequently missed questions from earlier self-tests and state the corrected concept behind each.