Engineer General Machinery study plan

Derive and apply the three fundamental load cases (axial, torsion, bending) to size a shaft, then add fatigue correction factors for a rotating shaft with a shoulder fillet

Select rolling-element bearings by computing equivalent dynamic load P = XVFr + YFa and solving for L10 life in hours at a stated speed

Size a spur gear pair for bending and pitting using the Lewis form factor and AGMA-style stress equations, and state which of the two failure modes governs

Choose a belt or chain drive for a given power and speed, and compute wrap angle, number of belts or chain links, and required center distance

Design a bolted joint (preload, joint stiffness, external load sharing) and decide whether separation or bolt fatigue governs

Specify a weld size for a fillet weld in torsion and in bending using the throat-area method, and compare against a bolted alternative

Select keys, splines, and interference fits for a given torque and check for shear and bearing failure

Size a compression spring for a stated load-deflection requirement and verify it is not surging at the operating frequency

Solve statics problems with friction, including wedge and screw-jack self-locking conditions, without referring to solutions

Compute mass moments of inertia for composite shapes and use them in a rotating-machinery acceleration problem

Apply work-energy and impulse-momentum to a mechanism or falling-mass impact, and state the assumptions used

Draw shear and bending moment diagrams for three indeterminate-looking beam cases and check the results against boundary conditions

Build a stress element from combined loading and compute principal stresses and the von Mises equivalent stress by hand

Predict failure mode from a Mohr's circle and a brittle-versus-ductile decision rule, and justify the choice of failure theory

Interpret a fatigue S-N curve, apply Marin correction factors, and compute a modified endurance limit

Read a fracture surface description (beach marks, chevron marks, intergranular versus transgranular) and map it to a likely failure mechanism

Match material selection to service conditions for five scenarios, using hardenability, toughness, corrosion resistance, and weldability as the deciding criteria

Specify a heat treatment sequence (normalize, austenitize, quench, temper) and predict the resulting microstructure and property change

Select a welding process and consumable for a given joint, thickness, and position, and state the preheat and post-weld heat treatment requirements

Identify the cause of three common weld defects (lack of fusion, porosity, hydrogen cracking) and the process change that prevents each

Compare a casting, forging, and machined-from-solid route for one part on cost, lead time, and inspectability

Apply the first and second laws to an open system and compute thermal efficiency for a Rankine or Brayton cycle with one irreversibility added

Compute head, power, and efficiency for a pump in a piping system, and locate the operating point where the pump curve meets the system curve

Use the affinity laws to predict flow, head, and power at a changed speed, and identify the risk of operating far from best efficiency point

Size a heat exchanger or compute a required surface area using LMTD and the effectiveness-NTU method, and state when each method is preferable

Compute friction loss and NPSH available for a suction line, and decide whether cavitation is a risk

Identify the code or standard that governs a given pressure vessel, lifting device, or power transmission guard, and cite the specific clause or section it comes from

Compute a minimum required thickness for a cylindrical shell under internal pressure and compare it to a measured thickness minus corrosion allowance

Write an inspection plan for one pressure-retaining item: what is examined, by which NDT method, at what interval, and what acceptance criterion applies

Explain the role of a pressure relief valve, set pressure, and accumulation limit, and verify a relief scenario is adequately protected

List the lockout/tagout and machine-guarding requirements that apply to a rotating-equipment maintenance task

Compute present worth, annual cost, and payback for two equipment alternatives and recommend one with the assumptions stated

Build a simple project schedule with a critical path and identify which activity delay moves the completion date

Apply a professional ethics decision framework to a conflict-of-interest or sign-off scenario and defend the chosen action

Take two full-length timed practice exams and log every missed item by domain and by error type (knowledge gap, misread, calculation, unit)