BRC – BANANAMAN REVIEW CENTER

MACHINE DESIGN AND SHOP PRACTICE PROBLEMS SET 1 pD  58 .8396   6

t  2s t 2  40 000 m  4.41 mm
0.00441

1. This radial distance in a gear is measured between the addendum

and dedendum circle, and is the sum of the addendum and the 5. What is the algebraic difference between the maximum limit and the
dedendum? How do you call this distance? corresponding basic size?
a) Addendum b) Whole depth a) Fundamental deviation b) Upper deviation
c) Working depth d) Space width c) Lower deviation d) Tolerance

Answer: b) Whole depth Answer: b) Upper Deviation

2. What is the polar section modulus of a solid shaft with a diameter of 6. A steel shaft 1.75 inches in diameter transmits 40 Hp at 1800 rpm.
101.6 mm? Assuming a modulus of rigidity of 12 x 106 psi, find the torsional
deflection of the shaft in degrees per foot length.
a) 209.5 cm3 b) 209.5 cm4
c) 205.9 cm3 d) 205.9 cm4 a) 0.0073 b) 0.0037
Answer: c) 205.9 cm 3 c) 0.0063 d) 0.00013

J 2J    63 000 Hp   63000 40  
32   32
Zj    T 
 D3  10.16 3  205.9 cm 3 32T  n   1800  0.0073 0.00013 radian 
  

Solution:
 1.75 12 x 106 
c D 16 16 4
L D4G  D4
G
JG
3. This minimum distance is measured between the non-driving side of Solution:
a tooth and the adjacent side of the mating tooth. It is the amount
by which the width of a tooth space exceeds the thickness of the
engaging tooth measured on the pitch circle. What is this distance? 7. What is the algebraic difference between the minimum limit and the
corresponding basic size?
a) Circular pitch b) Whole depth
c) Backlash d) Space width a) Fundamental deviation b) Upper deviation
c) Lower deviation d) Tolerance
Answer: c) Backlash
Answer: c) Lower Deviation

4. With the water interruptions prevailing in your town, you have been 8. A helical-coil spring has a mean coil diameter of 1 inch and a wire
asked to design an upright cylindrical water tank 6 meters in diameter of 1/8 inch. Determine the curve correction factor of the
diameter and 6 meters high, vented, and to be filled completely with spring.
water. Determine the minimum thickness of the tank plate if the
stress is limited to 40 Mpa. a) 1.144 b) 1.44
c) 1.1144 d) 1.1414
a) 3.3 mm b) 4.4 mm
c) 5.5 mm d) 8.8 mm Answer: Curve Correction Factor, Kc = 1.1144

1
 Answer: b) Thickness, t = 4.4 mm

p  gh  1000   9.8066   6   58 839 .6 Pa  kPa

Solution:
58.8396

Kw
K
4C 1 0.615 L
c 
4C  4 C 1.184   tan1   1  p 1  0.25 
1
 tan 0.09095  5.197
 1.1144 o

2C 1
 tan  tan 
Ks 1.0625 D D  0.875 
Solution: 2C  m   m
Solving for the torque required to overcome the collar friction,
9. This is either the upper or the lower deviation, depending on which
is closer to the basic size. How do you call this deviation? fFD c  0.2   200   0.5 
T    20 in lb
c
a) Fundamental deviation b) Upper deviation 2 2
c) Lower deviation d) Tolerance
Solving for the torque required to overcome the thread friction,
Answer: Fundamental deviation

10. A vise is equipped with a 1-inch single square thread, with 4 threads
per inch. The frictional radius of the collar is 0.5 inch. The coefficient FD  tan   f 200  0.875   0.09095 
of friction for both the collar and threads is 0.20. How much external  m 0.2
   25.93 in lb
Ts  
2  1 f tan 2 1 0.2  
 0.9095
 
torque must be applied to produce a force of 200 lb against the jaws Solving for the total torque,
of the vise?
T = Ts + Tc = 25.93 + 20 = 45.93 inches
a) 39.73 in-lb b) 33.97 in-lb
c) 37.93 in-lb d) 39.37 in-lb
11. What is the difference between the maximum and minimum size
Answer: c) 37.93 in-lb limits of a part?

Vise Jaw a) Allowance b) Tolerance

Screw c) Deviation d) Basic size
Collar Nut
Handle Answer: b) Tolerance
F = 200 lb
12. A helical-coil spring has a mean coil diameter of 1 inch and a wire
Solution: diameter of 1/8 inch. Determine the Wahl factor of the spring.
1
p 1   0.25 inch a) 1.148 b) 1.184
c) 1.418 d) 1.814
For the thread pitch,
Number of Threads per Inch 4
Answer: b) Wahl Factor, Kw = 1.184
2
 For the minor diameter, Di = Do – p = 1 – 0.25 = 0.75 inch
Dm 1
C  8
D For
Di 1the0.75mean or pitch diameter of the screw,
d 1
D o   0.875 inch Solution 8
:
m
2 2 4C  1 0.615 4 8  1 0.615
Kw      1.184
For the lead angle, 4C  4 C 4 8   8 8
1.5708 1.5708
t   0.31416 inch
pd 5
Solution:
13. It is the capacity of a material to absorb energy when it is deformed
elastically and then, upon unloading, to increase this energy. What is
this capacity of a material?
17. How do you call a structural member designed to support loads
perpendicular to its longitudinal axis?
a) Resilience b) Toughness
c) Rigidity d) Ductility a) Cantilever beam b) Beam
c) Overhanging beam d) Column
Answer: a) Resilience
Answer: b) Beam

14. A helical-coil spring has a mean coil diameter of 1 inch and a wire 18. Compute the speed of the gear mounted on a 52.5 mm diameter
diameter of 1/8 inch. Determine the value of Bergstrassar factor of shaft receiving power from a driving motor with 250 Hp.
the spring.
a) 2 182 rpm b) 2 071 rpm
a) 1.172 b) 1.712 c) 2 265 rpm d) 2 341 rpm
c) 1.217 d) 1.271
Answer: c) The speed, N = 2265 rpm
Answer: a) Bergstrassar Factor, KB = 1.1724
Solution:
Dm 1
C  8 4C  2 4 8  2 80 P 80  250  2 264 .92 rpm
N 
 3
D  52.5  3
d1.172418 KB   
4C  3 4 8  3
Solution:  
From PSME Code:  25.4 
15. How do you call the strain energy per unit volume required to stress
a material from an unloaded state to the point of yielding?

a) Modulus of roughness 16. Compute the tooth thickness of a 14.5o spur gear with diametral pitch of 5.
b) Modulus of elasticity
a) 0.23140 inch b) 0.31416 inch
c) Modulus of rigidity
c) 0.43140 inch d) 0.03140 inch
d) Modulus of resilience
Answer: b) Tooth thickness, t = 0.31416 inch
Answer: d) Modulus of Resilience
3
19. It is a load applied transversely to longitudinal axis of
member. How do you call this load?

a) Bending load b) Combined load

c) Distributed load d) Cyclic load

Answer: a) Bending load

20. What is a load distributed over an entire area?

a) Bending load b) Combined load

c) Distributed load d) Cyclic load

Answer: c) Distributed load

4
 25. How do you call a statistical data used to identify the most likely
failure modes?
21. Compute the working strength of 1 inch bolt which is screwed up
tightly in packed joint when the allowable working stress is 13000 a) Finite element analysis
psi. b) Fault free analysis
c) Failure analysis
a) 3 600 lb b) 3 950 lb d) Random analysis
c) 3 900 lb d) 3 800 lb
Answer: b) Fault free analysis
Answer c) The working strength, W = 3 900 lb
26. A hollow iron pipe to be designed as a column has an outside
Solution: From machinery’s Handbook, page 1149: diameter of 240 mm and is subjected to a force of 80 KN. Find the
  
W  s t 0.55d 2  0.25d  13 000  0.55 1
2
 0.251  3 900 lb
pipe thickness if the compressive stress is limited to 16 MPa.


22. It is a design approach where no catastrophic loss can occur as a
a. 5.85 mm
c. 7.85 mm
b. 6.85 mm
d. 8.85 mm

result of a component failure. What is this design approach? Answer: b) Pipe thickness, t = 6.85 mm
a) Fail-safe design approach Solution:
b) Fault free analysis approach
c) Manifest danger approach
4  80
Inside Diameter,
d) Redundancy approach 4F
D  D2    0.24 2   0.2263 m  226.3 mm
Answer: a) Fail-safe design approach
i o  16 000 
23. It is the condition of a machine element when it is completely s
inoperable, cannot perform its intended function adequately, or is
unreliable for continued safe use. What do you call this condition?

a) Fail-safe condition b) Failure condition

c) Critical condition d) Salvage condition

24. Compute the nominal shear stress at the surface, in MPa, for a 50 Do  Di 240  226.3
mm diameter shaft that is subjected to a torque of 0.48 kN-m. t 2  2  6.85 mm
Thickness of the
Pipe,

a) 16.95 b) 21.65 MPa

c) 19.56 d) 25.12

Answer: Shear Stress, ss = 19.56 MPa

16 T 16  0.48 
s    19 556.96 kPa  19.56
 27. It is a computational method used for solving set of a specific purpose. What is this computational method?
complex shapes, such as those found in
machinery; replaces the complex shape with a a) Finite element analysis
set of simple elements interconnected at a finite
s b) Numerical method of analysis
  0.050 
3
Solution: D3 c) Fault free analysis
d) Synthesis
Answer: a) Finite element analysis
a) 18.4o b) 20o
c) 14.5o d) 20.5o

Answer: a) Pitch angle of the pinion = 18.4o

 Tp 
  tan1    tan1  14   18.4o
 T  42 
Solution:  g
28. A uniform beam 12 meters long is fixed at one end. It has a uniform


weight of 50 kg/m along its length. A load of 20 kgs. is suspended on
31. How do you call the diameter of the imaginary cylinder that bounds
the beam 4 m from the free end. The moment at the fixed end is
the crest of an external thread and the roots of an internal thread?
a. 3760 kg-m b. 0.0 kg-m
a) Mean diameter b) Stress diameter
c. 60 kg-m d. 4800 kg-m
c) Minor diameter d) Major diameter
Answer: a) 3760 kg-m
Answer: d) Major diameter
Solution: Bending Moment,
32. A 20o straight-tooth bevel pinion having 14 teeth and a diametral
M  6  600   8  20   3 760 kg  m pitch of 6 teeth/inch drives a 32-tooth gear. The two shafts are at
right angles and in the same plane. The pinion is to transmit 1800
rpm and transmitting 50 hp. Determine the pitch diameters of the
W = 50 (12) = 600 kg gears.
F = 20 kgs a) 2.33 inches and 5.36 inches
b) 3.23 inches and 3.56 inches
c) 5.36 inches and 6.36 inches
d) 2.33 inches and 2.33 inches
6m
8m Answer: a) 2.33 inches and 5.36 inches

Solution:

29. When a hot part is cooled suddenly by quenching, there is a) Thermal-shock failure b) Thermal fatigue
momentarily a high temperature gradient that induces a stress c) Honing d) Quenching
gradient. Some metal parts under certain conditions crack as a
result. How do you call this phenomenon? Answer: a) Thermal-shock failure
 T1 14
30. A 20o straight-tooth bevel pinion having 14 teeth and a diametral D1   2.33 inches
Pd 6
pitch of 6 teeth/inch drives a 42-tooth gear. The two shafts are at
right angles and in the same plane. Find the pitch angle of the T  32
D  D  2   2.33   5.36 inches
pinion. 2 1 
 1T 

33. It is a measure of the change in length of a material subjected to a

change in temperature. How do you call this property of the
material?

a) Toughness
b) Coefficient of thermal expansion
c) Thermal conductivity
d) Electric Resistivity 35. What is a condition where one surface is comparatively free of stress?

Answer: b) Coefficient of thermal expansion a) Octahedral plane b) Biaxial or Plane stress

c) Strain plane d) Principal normal stress

Answer: b) Biaxial or Plane stress

34. A 1-inch diameter shaft has a single disc weighing 75 lb mounted

midway between two bearings 20” apart. Find the lowest critical 36. A flywheel weighing 457 kg has a radius of 375 mm. How much
speed in rpm. Neglect the weight of the shaft. Assume that the energy, in N-m, does the flywheel loss from 3 rps to 2.8 rps?
modulus of elasticity is 30 x 106 psi.
a) 368 b) 150
a) 2038 rpm b) 2308 rpm c) 1474 d) 38
c) 2380 rpm d) 2803
Answer: c) Flywheel Energy =1474
rpm Solution:
Solution:
W = 75 lb
V1  2   0.375   3  7.069 m / s

10” 10”
V2  2   0.375   2.8  6.597 m / s


m V2 V2  2  2

D = 1 inch E = 30 x 106 psiL = 20 inches
  D4   1 4 7.069 6.597
KE  1 2 457  1473 .91 N  m
2  2

Moment of Inertia, I  64 64  0.0491 in.4

Solving for the lowest critical speed,

cr 
576 E I g  576   30 x 106   0.0491   213.39 rad / s
 32.2 
W L3 37. How do you call the circle on a gear that corresponds to the contact
 75  20 3 surface of the friction wheel?

Ncr 30 cr 30  213.39 

   2 037.68 a) Addendum circle b) Root circle
c) Pitch circle d) Base circle
rpm
 
Answer: c) Pitch circle
 steels and for use where fatigue resistance and long endurance are
needed; this is also good for shock and impact loads.

a) Chrome silicon b) Chrome vanadium

c) hard-drawn wire d) Oil-tempered wire

Answer: b) Chrome Vanadium

38. A triple threaded worm has a pitch diameter of 3 inches. The wheel
40. What is the largest roller chain size that can be used for power
has 25 teeth and a pitch diameter of 5 inches. Material for both the
transmission at a sprocket speed of 1000 rpm?
wheel and the wheel is phosphor bronze. Determine the helix angle
of the gear. a) RC 35 b) RC 50
c) RC 80 d) RC 60
a) 11.31 o
b) 13.11 o

c) 11.13o d) 10.13o
Answer: d) RC 60
2
Answer: Gear Helix angle = 11.31 o
 900  3
p ma   
Note: Max. Chain Pitch in x n
Solution:
Dg   5 Practice:
2
pmax   900  3
Pc   25  0.6283 inch 
1000

 0.932 in
Circular pitch of the worm gear, Tg
Since RC 80, p = 1 inch exceeds the maximum and RC 70 does not
Where, Pc = Pa = pitch of the
exist, and then use RC 60.
worm

41. These are gears with teeth formed on conical surfaces and are used
Solving for the lead, L = Nt Pa = 3(0.6283) = 1.8849 inches
mostly for transmitting motion between intersecting shafts. How do
 the lead angle of the worm, you call these gears?
Solving for 
  tan1 L 1
o
 1.8849  11.31
  tan 
3 a) Spur gears b) Helical gears
D 



 w  39. This material is the most popular alloy spring steel for conditions involving
higher stresses than can be used with the high-carbon
For the helix angle, and considering that the shafts angle
is 90o,

g =  = 11.31o ans.
 c) Bevel gears d) Worm gearings

42. A single square thread power screw is to raise a load of 70 kN. The
Answer: c) Bevel gears screw has a major diameter of 36 mm and a pitch of 6 mm. The
coefficient of thread friction and collar friction are 0.13 and 0.10
respectively. If the collar mean diameter is 90 mm and the screw
turns at 60 rpm, find the axial linear speed of the screw. D3 N 1 3
P   10 Hp
a) 5 mm/s b) 6 mm/s Solution: 38  380 
c) 7 mm/s d) 5.5 mm/s 38
45. A spur pinion rotates at 600 rpm and transmits 25 kW to a mating
Answer: b) 6 mm/s gear. The pitch diameter of the pinion is 100 mm, and the pressure
angle is 20o. Determine the tangential load, in N.
Solution: For the linear speed of the screw,
a) 7660 b) 6790
Vn = n (L) = (60 rpm)(6 mm/rev) = 360 mm/min = 6 mm/s c) 3900 d) 3098

 2  30 P   2   30  25 000  
F 
         
t
D n 0.10 N 600  
7 957.75 
Solution:      

43. A double thread ACME screw driven by a motor at 400 rpm raises
the attached load of 900 kg at a speed of 10 m/min. The screw has
a pitch diameter of 36 mm; the coefficient of friction on threads is
0.15. The friction torque on the thrust bearing of the motor is taken 46. A bearing that primarily guides the motion of a machine member
as 20 without specific regard to the direction of load application.
% of the total input. Determine the lead angle.
a) Journal bearing
a) 12.465o b) 14.265o b) Clearance bearing
c) 15.462o d) 16.452o c) Guide bearing
d) Thrust bearing
Answer: a) 12.465o
Answer: c) Guide bearing
Solution:
V
L  10  0.025 m  25 mm 47. A multiple-disk clutch, composed of three plates with a small
For the n 40 diameter of 150 mm and large diameter of 200 mm, is designed to
lead, 0 transmit 100 kW at 3000 rpm at a coefficient of friction of 0.5.
 L   25  Determine the spring force needed to engage the clutch.
  tan1    tan1    12.465 o
 D  36  a) 2820 N b) 2428 N
For the lead angle,  m
c) 5460 N d) 3638 N


44. What Hp can a 1-inch diameter short shaft transmit at 380 rpm?
 Answer: 3638 N
a) 3 Hp b) 18 Hp
c) 10 Hp d) 7.1 Hp
Solution:
Answer: c) 10 Hp
30 P 30 100  0.3183 kN  m  318 .3 N  m
T 
 
n  3000

  D  d 
T  f  P  rf  Nfs  f  P 
  fs 49. What is the bursting steam pressure of a hemispherical steel shell
N  4  with a diameter of 100 inches and made of 0.0635-m thick steel
plate, if the joint efficiency is 70 % and the tensile strength is 60
000 psi?
4T 4  318 300 
P   3637 .71 N
f   D  d  0.5  200  150  a) 4 020 psi b) 4 200 psi
c) 2 400 psi d) 2 040 psi
N fs  2
Answer: b) 4200 psi

 63 .5
4

 
in  60 000 lb / in 2  0.70 
4 t s lE j  25.4   4 200 psi
p D  100 in.
Solution:

Where, p = bursting pressure, psi

sl = shell stress, psi
t = shell thickness, inches
D = shell diameter, inches
Ej = joint efficiency
48. A wire rope lifts a load of 10 kips at a maximum speed of 1000 feet
per minute, attained in 5 seconds starting from rest. The rope has a Note: For the longitudinal stress of the thin-walled cylinder, and the
metallic cross sectional area of 0.4 in2. Determine the maximum stress for spherical tank:
tensile stress on the rope in ksi. pD
a) 26.2 b) 25.0 sL 
c) 27.6 d) 32.4 4 t Ej
Answer: c) maximum tensile stress = 27.6
MPa
50. A cylinder having an internal diameter if 508 mm and external
Solution: diameter if 914.4 mm is subjected to an internal pressure of 69 MPa

914.4   2  508
  
2   914.4 
2
and an external pressure of 14 MPa. Determine the hoop stress at
69 MPa  mm   mm   2 14 MPa  mm the
inner surface of the cylinder.
2 2
2 2 2 2
ps o ro

pi ro  ri  2  
 
     
ti  914.4 2  508 2
2 r2r
a) 90.11 o MPa mm   b) 91.10
i
 mm c) 911.0 MPa d) 19.10 Mpa
 2
2 
V1  Vo 1000 / 60   0 Answer: a) 90.11 MPaa
a  fps 2  3.33
t 5
Solution:
F a  3.33 
 
 WL 1 
  10 000  1    11 034 .16 lb
 g  32.2
 sti = 90.11 Mpa

11,034.16 Where,
S  27585.4 psi  27.6 ksi
t sti = maximum tangential or hoop stress at the inside ri
0.4
= inside radius, mm
pi = internal pressure, Mpa

ro = outside radius, mm
po = external pressure, Mpa 2  63 000 
2T   2.1
L
Note: For the maximum tangential or hoop stress at the Key length based on ssbD inches 15000
 1 4
outside, shear,
4T 4  63 000 
2pr p r r 2
 2
L 
s c t D 30 000 1  4
 2.1


Key length based on
2 compression,

sto  i i
r r2
o o
2
i
Therefore, use L = 2.1 inches
o i
52. Which of the following are the compositions of stainless steel 302?

a) 18 % chromium and 8 % nickel

b) 18 % nickel and 8 % chromium
c) 18 % chromium and 8 % phosphor bronze
d) 18 % bronze and 8 % vanadium

Answer: a) 18 % chromium and 8 % nickel

e

51. What length of a square key is required for a 4-in diameter shaft
 tan 3.3125 1 0.13 tan 3.3125  100
o o
 0.10  90  
%
  12.53 %

transmitting 1000 hp at 1000 rpm? The allowable shear and

compressive stresses in the key are 15 ksi and 30 ksi, respectively. tan 3.3125o  0.10  1 0.13 tan 3.3125 o

 
a) 2.1 inches b) 2.8 inches
c) 3.2 inches d) 4.2 inches 33
53. The root diameter of a double square thread is 0.55 inch. The screw
Answer: a) 2.1 inches has a pitch of 0.2 inch. Find the number of thread per inch.

Solution: a) 0.2 threads/inch b) 10 threads/inch

63000 Hp 63000 1000  in 
c) 5 threads/inch d) 2.5 threads/inch
T 
63000   lb
Transmitted torque, n 1000 Answer: TPI = 5 threads per inch
D
b  , for good proportion Solution:
1
Key width, 4 TPI   1  5 threads / inch
The number of threads per
p 0.2
inch,
54. A single square thread power screw is to raise a load of 70 kN. The
screw has a major diameter of 36 mm and a pitch of 6 mm. The Solution:
2  r  r   2   125   100  
3 3 3 3
coefficient of thread friction and collar friction are 0.13 and 0.10
respectively. If the collar mean diameter is 90 mm and the screw rf  o i   112 .96 mm
turns
collar. at 60 rpm, find the combined efficiency of the screw and 3  r 2  r2   3   125  2  100  2 
Friction radius,  o i   
a) 15.32 % b) 12.53 %
c) 13.52 % d) 15.97 % Surface Area of contact,

Answer: b) 12.53 % A f  2rf b  2 0.11296  0.125   0.0887 m 2

Solution:
1 1 ForcWe n=o7r0mNal to the surface of contact,
h
mm
p  6  3
    Fn  pA f   70  0.0887   6.209
2 2 kN
For the depth of the   
thread,
For the mean diameter of the
screw, Power Capacity,
 n Tf   n  f F r  870 
P   0.30  6.209  0.11296   19.2 kW  25.74 Hp
Dm  Do  h  36  3  33 mm p 30
nf
30
30
 For the lead angle,
  L   p  56. Three extension springs are hooked in series that support a single
  tan 1    tan1    tan1  6    3.3123 o weight of 100
two springs arekg. The6 first
rated kN/m spring
[Link]
rated at 4the
kN/m and the other
equivalent
D D
 m  m  33  stiffDniess of the three springs.
D m
a) 1 .7 1 kN/m b) 5 kN/m

tan 1  f tan   100 %  c) 2D.7o1 kN/m d) 3.71 kN/m
e  f c Dc 
tan   f    1 f tan  
Answer: a) 1.71 kN/m
 Dm 
Solving for the
Efficiency, Solution:

1 1 1 1 1 1 1 1 1 34 7
         
k e k1 k 2 k 3 4 6 6 4 3 12 12

12
k  1.71 kN / m
55. Determine the power capacity of a cone clutch under uniform e
7
pressure and assuming the following conditions: major diameter =
250 mm; minor diameter = 200 mm; length of conical elements in 57. These springs are made from one or more flat strips of brass,
contact = 125 mm; rotational speed = 870 rpm; coefficient of bronze, steel or other materials loaded as cantilevers or simple
beam.
friction
= 0.30; and allowable pressure = 70 kPa. a) Torsion springs b) Leaf springs
c) Garter springs d) Drawbar springs
a) 25.74 Hp b) 24.75 Hp
c) 27.45 Hp d) 24.57 Hp Answer: b) Leaf Springs

Answer: a) 25.74 Hp
58. A flat belt is 6 inches wide and 1/3 inch thick and transmits 20 Hp.
The center distance is 8 ft. The driving pulley is 6 inches in diameter
and rotates at 2 000 rpm such that the loose side of the belt is on
top. The driven pulley is 18 inches in diameter. The belt material is
0.035 lb/in3 and the coefficient of friction is 0.30. Determine the belt
net tension.
Answer: a) 2.578
a) 201 lb b) 210 lb
c) 102 lb d) 120 lb 60. This refers to the space between adjacent coils when the spring is
compressed to its operating length.
Answer: b) 210 lb
a) Coil clearance b) Pitch
Solution: c) Lead d) Deflection
2 T 2  63 000 Hp   2   63 000  20  
F  F1  F2     2000   210 lb Answer: a) Coil clearance
D D n   6  

Other Solution: 61. Select a deep-groove ball bearing to carry a radial load Fx = 800 lb
and a thrust load Fz = 700 lb at 1750 rpm. The service is 8
 hr/day,
 6  but it is not continuous; design for 20 000 hr. The operation is smooth
Vm   D n     2 000   3141 .59 with little vibration; the outer ring rotates. Determine the design life
fpm 12
  in mr with no more than 10 % failure.

FFF 33 000 Hp 33 000  20  a) 20100 mr b) 2100 mr

   210
lb
1 2
Vm 3141 .59 c) 2001 mr d) 1200 mr

Answer: b) 2100 mr
 AE     2  1.3    
   0.025  207 000 000 000   52837.66 N
2
F    D E 
L 2.5 1000  4
L4  
Solution:

 20 000  60 1750

B1   Hrs   60 min s / hr   rpm    2100 mr
59. A pulley 600 mm in diameter transmits 40 kW at 500 rpm. The arc of
contact between the belt and pulley is 155 o, the coefficient of friction 6
between belt and pulley is 0.35 and the safe working stress of the 0 10
belt is 2.1 MPa. Determine the belt tensions ratio, neglecting the
effect of centrifugal force.

a) 2.578 b) 2.857
c) 5.287 d) 5.782

Solution: 62. Determine the Hp lost when a collar is loaded with 2000 lb, rotates at
F1   50 rpm, and has a coefficient of friction of 0.15. The outside diameter
0.35 155  of the collar is 4 inches and the inside diameter is 2 inches.
e
f 

  e 180
   2.578
F2 a) 0.7314 Hp b) 0.3714 Hp
c) 0.4713 Hp d) 0.4371 Hp Answer: a) Clearance

Answer: b) 0.3714 Hp 66. A 50-mm diameter shaft is to transmit 12 kW power at a speed of

500 rpm, determine the mean diameter of the pin, under double
Solution: shear, for a material having a safe unit stress of 40 N/mm2.

a) 11.08 mm b) 12.08 mm
fHp
Tf n f W rf n 0.15  2000 lb  1.56 inches   50 rpm 
 
63000 63000  c) 13.08 mm d) 10.08 mm
 63000 0.3714

2  r 3  r 3  2   2  1 
3 3 Answer: b) Diameter of the pin = 12.08 mm
rf  o i   1.56 inches
 
 3  r 2 r 2 3   3 2
 1
2

Where,  o i    Solution:

63. In a lathe machine, it is the diameter of the largest workpiece it can

Transmitted Torque,
rotate in a chuck or between centers without hitting the bed.

a) Chuck diameter
between centersb) Swingd) Spindle diameter 2T  ssbLD
2  D   28.13   175   112.5 
c) Distance F   2   s bL  14 000      10
014.74 lb  
p
D D s
D  25.4  25.4 1200
 
p p  p 
Answer: b) Swing 30 P 30 12 000 
T   229 .183 N  m  229 183 N 
64. What load in N must be applied to a 25 mm round steel bar 2.5 m
long (E = 207 Gpa) to stretch the bar 1.3 mm? mm
n  500
a) 42 000 N b) 52 840 N
c) 53 000 N d) 60 000 N 2T 2  229 183 
F    9167 .32 N
s
Answer: b) The load, 52 840 N Pin Shearing Force, D 50

Fs 4 Fs 2 Fs
ss   
Solution: Pin Mean Diameter,
2As 2 d2 d2

The load,
2 Fs 2
d 
 9 167 .32   12.08 mm
 ss
  40 

65. This is a general term that refers to the mating of cylindrical parts
such as bolt or a hole; it is used only when the internal member is
smaller that the external member. How do you call this?

a) Clearance b) Interference
c) Allowance d) Tolerance
67. This is a lubrication condition where non-conformal surfaces are d) Hydrostatic lubrication
completely separated by lubricant film and no asperities are in
contact. How do you call this lubrication condition?

a) Elastohydrodynamic lubrication
b) Boundary lubrication
c) Hydrodynamic lubrication
required diameter of the bolts circle based on an average shearing Answer: a) Bolt Circle diameter = 245 mm
stress of 27.5 MPa.
Solution:
a) 245 mm b) 254 mm
c) 452 mm d) 425 mm

Answer: a) Elastohydodynamic lubrication 8T 8 30  P  8 30  350 

DB    0.245 m  245 mm
  0.018   27 500  650
2 2
 ss d n  d ss n n
2 2 2
68. A 1200 mm cast iron pulley is fastened to 112.5 mm shaft by means
B
B
 6
of a 28.13 mm square key 175 mm long. The key and shaft have a  ss d 2 DB n n
shearing stress of 14 000 psi. Determine the force acting at the 30 P
B  n
pulley that will shear the key. Note: Torque Based on T
8
Shear,
a) 10 015 lb b) 11 005 lb
c) 11 050 lb d) 10 501 lb 70. How do you call the flattened end of a shank, and intended to fit
into a driving slot in the socket?

Answer: a) The force acting on the pulley = 10 015 lb a) Handle b) Tang

c) Relief d) Tip
Solution:

Shaft Pin Answer: b) Tang

71. If a sleeve bearing has an outside diameter of 38.1 mm and a length

T of 50.8 mm, the wall thickness is 3/16 inch. The bearing is subjected
to a radial load of 500 kg. What is the bearing pressure, in psi?
a) 904 psi b) 409 psi
c) 490 psi d) 940 psi
ss bLD  Torque based on shear, in  lb
T 2 Answer: c) Bearing pressure = 490 psi
Where,
Solution:
For bearing or projected area,

A
 50 .8
LD 
  38 .1
in.  
in.  2 3 in  2.25 in 2
B
 25.4  16 
  
25.4

p
W

 500 kg   2.205 lb / kg   490 psi
AB 2.25 in 2
Bearing pressure,
69. A 75-mm diameter shaft is transmitting 350 kW at 650 rpm. A flange
coupling is used and has 6 bolts, each 18 mm in diameter. Find the
72. This material is the most popular alloy spring steel for conditions involving higher stresses than can be used with the high-carbon steels and
 for use where fatigue resistance and long endurance are needed; 75. For an American Standard Screw Threads, what does 6-32 UNC
this is also good for shock and impact loads. designate?
a) Chrome silicon b) Chrome vanadium a) Size 6, 32 threads per inch, coarse thread
c) hard-drawn wire d) Oil-tempered wire b) 6 inches basic diameter, 32 threads per inch, coarse thread
c) Size 6, 32 threads per inch, fine thread
Answer: b) Chrome Vanadium d) 32 inches basic diameter, 6 threads per inch, coarse thread
73. Determine the minimum whole depth of spur gear of 14.5 o involute Answer: a) Size 6, 32 threads per inch, coarse thread
type with diametral pitch of 24 and circular pitch of 0.1309 inch.
 Note: 6 stands for the designated size, 32 stands for the
a) 0.09000 inch b) 0.08900 inch
number of threads per inch, UNC stands for Coarse threads
c) 0.0899 inch d) 0.089758 inch
76. Determine the Poisson’s ratio of a material whose modulus of
Answer: c) Whole depth = 0.0899 inch elasticity is 200 GPa and whose modulus of rigidity is 80 GPa.
Solution: a) 0.33 b) 0.25
c) 0.38 d) 0.22
2.157 2.157 Answer: b) Poisson’s ratio = 0.25
h   0.089875 inch
From Vallance, page 262: pd 24 E
G
74. A parallel helical gear set was a 17-tooth pinion driving a 34-tooth Solution: 2(1  ) E = 200GPa, G = 80GPa:
gear. The pinion has a right-hand helix angle of 30 , a normal o
  0.25
pressure angle of 20o, and a normal diametral pitch of 5 teeth/in.
Find the axial circular pitches.
77. A steel has a BHN = 300. What is its approximate ultimate strength
a) 1.2566 inches/tooth b) 1.6625 inches/tooth
in ksi?
c) 1.6526 inches/tooth d) 1.6256 inches/tooth
a) 300 ksi b) 150 ksi
Answer: a) Axial circular pitch = 1.2566 inches/tooth
c) 75 ksi d) 200 ksi

Pcn  0.62832  0.72552 inch / tooth Answer: b) Ultimate Strength = 150 ksi
Pc 
cos cos 30o
Solution:
 Solution: Su  0.5(BHN), ksi

Pc  0.72552  1.2566 inches / tooth

Pa  o
tan  tan 30
78. If the angular deformation of a solid shaft should not to exceed 1o in
2r r  2   2   1 
3 3 3 3
a length of 1.8 m and the allowable shearing stress is 83 MMa, what
is
the diameter of the shaft? Assume that the shaft material has G = 77 rf  2  1.56 inches
3  r 2  ri 2   3   3  1
o 2
x 106 kPa. 
Where,  o i   
a) 222.34 mm b) 234.22 mm Answer: a) Shaft diameter = 222.34 mm
c) 23.42 cm d) 24.22 cm
 of hammer blows on the surface.
81. It is a process that produces
residual compressive stress on the a) Nitriding b) Shot blasting
machine part, which uses a series
 3
c) Peening d) Tempering
32 D s 
 s 

TL 32T L Answer: c) Peening

    2ss L
 
16 

Solution: JG D4G D 4 G DG
82. Two shafts 3.6 m between centers carry pulleys 1.2 m in diameter
and 0.91 m in diameter respectively, connected by a crossed belt. It
is desired to put the belt on as an open belt. How long a piece must
2 ss L 2 83 000 1.8 be cut of it?
D   222.34
mm
G    a) 303.3 mm b) 330 mm
1o  
 77 x 106  c) 333.0 mm d) 330.3 mm
 180o 
Answer: Length to be cut off = 303.3 mm

Solution: For the length of an open belt

connection,

79. How do you call the process of producing the residual

compressive stress of machine parts, which is performed by   D 2  D1  2  1200  910  2
     
directingstream
velocity
be the a high
of hardened balls or pellets at the surface to Lo  D1  D 2  2C      1200  910  2 3600  4  3600  10 520.22 mm
treated. 2 4C 2

For the length of belt for crossed belt connection,

a) Nitriding b) Shot blasting
c) Peening d) Tempering 
    D D 
2
   1200 
    910  2  
Answer: b) Shot Lc D1 D2 2C 2
 1   1200 91 2 3600
blasting
0  
2 4C 2 4 3600
80. Determine the Hp lost when a collar is loaded with 2000 lb, rotates
at
50 rpm, and has a coefficient of friction of 0.15. The outside Solving for the difference of lengths,
diameter of the collar is 4 inches and the inside diameter is 2 inches.
L  Lc  Lo  10 823 .55 10 520 .22  303 .33 mm
a) 0.7314 Hp b) 0.3714 Hp
c) 0.4713 Hp d) 0.4371 Hp 83. It is a surface-hardening process for alloy steels in which the
material is heated to 950 oF in a nitrogen atmosphere, typically
Answer: b) Frictional Horsepower = 0.3714 Hp ammonia gas, followed by slow cooling.
Solution: a) Quenching b) Nitriding
fHp 
Tf n f W rf n 0.15 2000 lb  1.56 inches   50 rp m c) Shot blasting d) Peening
  
0.3714
63000 63000 63000
Answer: b) Nitriding
84. A 20-tooth motor sprocket, running at 1200 rpm, drives a blower at
87. A right-handed single-thread hardened-steel worm has a catalog
a speed ratio of 4:1. Using the largest permissible chain size and the
rating of 2.25 kW at 650 rpm when meshed with a 48-tooth cast-
largest permissible center distance of 80 pitches, what length of
steel gear. The axial pitch of the worm is 25 mm, normal pressure
chain in pitches is required to connect the sprockets?
angle is 14.5o, and the pitch diameter of the worm is 100 mm. The
coefficient of friction is 0.085. Determine the shafts center distance.
a) 200 pitches b) 212 pitches
c) 216 pitches d) 220 pitches a) 241 mm b) 142 mm
c) 412 mm d) 124 mm
Answer: b) Chain length = 21 pitches
Answer: a) Center distance = 241 mm
NN N N 2
Solution: Lc  t1 t2
 2Cp 
t2 t1 
[Link] Solution:
2 40Cp  n T D cos  D
g g g
Speed Ratio, SR  w
 w
  
85. Which of the following gases is typically used in nitriding process g ng Tw D w sin  D w tan 
of surface hardening?
L p 25
Tan    0.07958    4.55
o
a) Nitrogen gas b) Carbon dioxide
Dw Dw  100
c) Ammonia gas d) Hydrogen gas

Answer: c) Ammonia Pitch diameter of the gear,

gas
86. A 20-kW motor, running at 1200 rpm, drives a 400 mm diameter  Tg  Tg   p   Tg   p   48   25 
D   tan    D          381.97 mm
D
g  w  T  w  D   T   1   
pulley at a belt tension ratio of 2.4. If the belt’s tight side tension is  w T  w  w  w   
only 1200 N, determine the transmission efficiency.
Dw  Dg 100  381.97
a) 87.97 % b) 84.58 % C   241 mm
Center Distance, 2 2
c) 85.66 % d) 86.55 %

Answer: a) Transmission Efficiency = 87.97

88. Which of the following is the benefit in using nitriding as a
%
surface- hardening process for alloy steels?

a) Improvement of endurance strength, 50 % or more

Solution:
b) Improvement of endurance strength, less than 50 %
c) Improvement of endurance strength, more than 50 %
Tout    n  D   n  D   1200    0.40   d) 80 % improvement on the endurance strength
n   F   
1200    1200 
Poutput F F 
30   net   1 2  30  2  2.4 
 30 2  30 2
       0.8797 Answer: a) Improvement of endurance strength, 50 % or more
Pinput   20000
Pinput Pinput

Pinput
  T  D g  
1  w   1  2  5  o
  tan
  tan 
Tg D
   9.46
  w   20  3 

89. A 20o straight-tooth bevel pinion having 14 teeth and a diametral

pitch of 6 teeth/inch drives a 42-tooth gear. The two shafts are at
right angles and in the same plane. Find the pitch angle of the 92. A 36-tooth pinion turning at 300 rpm drives 120-tooth gear of 14.5 o
pinion. involute full depth pressure angle. Determine the rpm of the driven
gear.
a) 18.4o b) 20o
c) 14.5o d) 20.5o a) 60 rpm b) 45 rpm
c) 75 rpm d) 90 rpm
Answer: a) Pitch angle = 18.4 o
Answer: d) 90 rpm
 Tp 
  tan 
1   tan1  14   18.4o Solution:

Solution:  Tg  42 
  Tp 
     300  36   90 rpm
nn
90. A triple-thread worm has a lead angle of 17o and a pitch diameter of g p  120 
Tg
2.2802 inches. Find the center distance when the worm is mated 
with
a wheel of 48 teeth. 93. If two parallel shafts are connected by cylinders in pure rolling
contact and turning in the same direction, and having a speed ratio
a) 6.72 inches b) 7.26 inches of 2.75, what is the Center distance of the two shafts assuming that
c) 6.27 inches d) 7.62 the diameter of the smaller cylinder is 22 cm?

inches Answer: a) Center Distance = 6.72 a) 18.25 cm b) 19.25 cm

c) 20.25 cm d) 17.25 cm
inches Solution:
 Tg
D    48  Answer: b) Center Distance = 19.25 cm
 2.2802  tan17  11.154
o
 tan   
D Solution:
inches
w  Tw 
g 3

Dw  Dg 2.2802 11.154
C   6.72 inches
D 2  SR  D1   2.75 22  60.5
Diameter of the bigger cylinder,
cm
2 2
a) 4.69o b) 9.46o
91. A double-thread worm has a pitch diameter of 3 inches. The wheel c) 6.49o d) 6.94o
has 20 teeth and a pitch diameter of 5 inches. Find the gear helix
angle. Answer: b) Gear helix angle = 9.46o
Solution: D 2  D1 60.5  22
C   19.25 cm
Center distance, 2 2

94. In estimating the actual endurance strength of steel parts, one of

the factors to be considered is the material factor, which of the
following is the recommended material factor for cast steel?

a) 0.70 b) 0.80
c) 0.75 d) 1.0
 Answer: a) Material factor for cast steel = 0.70

95. How do you call the level of stress that the part will be permitted
to see under operating conditions?
98. Two extension coil springs are hooked in series that support a single
a) Yield stress b) Endurance stress
weight of 100 kg. The first spring is rated at 4 kN/m and the other
c) Design stress d) Ultimate stress
spring is rated at 6 kN/m. Determine the total deflection of the
springs.
Answer; c) Design Stress a) 408.6 mm b) 486.0 mm
c) 480.6 mm d) 460.8 mm
96. Which of the following column formulas is applicable to cast
iron columns?
Answer: a) Spring Deflection = 408.6 mm
a) Euler’s formula b) [Link]’s formula
Solution:  k1  k 2  46
C) Secant formula d) Straight line formula  F F    100 kg  9.8066 N / kg  
   408.6 m
 
4 6 
Answer: d) Straight line formula
t 1 2 F k k 
k1 k2  1 2   
o Ans. D. Straight line formula. Cast iron columns are usually
designed on the basis of 99. If the ultimate shear strength of a steel plates is 42 000 psi, what
P L  force is necessary to punch a 0.75 inch diameter hole in a 0.625 inch
 9000  40 e  a Straight line formula
A  k  thick plate?

o Where the slenderness ratio Le/k should not exceed 70. a) 61 850 lb b) 65 810 lb
c) 61 580 lb d) 60 185 lb

97. Which of the following ferrous metals has the lowest carbon content? Answer: a) Punching force = 61 850 lb

a) Carbon steel b) Wrought iron Solution:

c) Cast iron d) SAE 4140 
F  s u A s  s u  d t   42000 lb / in 2   0.75 in  0.625 in   61850.1 lb
Answer: b) Wrought iron
[Link] stiffness is the main criterion in selecting a material, which of the
o Wrought iron usually contains less than 0.04% C; steel usually following is the most economical choice?
has less than 2.5% C; cast iron has more than 1.7% C; SAE
4140 has approximately 0.4% C. a) SAE 3130
b) SAE 1020
c) SAE 6150
d) AISI 301, ¼ hard stainless steel
o Ans. B. SAE 1020- plain carbon steel.
 o Note: All of the above materials are steel with practically equal
modulus of elasticity. The three other materials are alloy steels
that are relatively more expensive.

Solving for the maximum induced shear stress,

ss max   kts ss   1.25  36.84   46.05 MPa

101. Which of the following materials can easily be machined?

104. A steam engine that has a stroke of 12 inches has an overhung
a) AISI C1020 b) AISI C1112 crank of 11 inches. The maximum tangential force, P, on the crank
c) AISI C1030 d) AISI C1010 may be assumed as 75000 lb. Assuming an allowable stress in shear
as 4400 psi, determine the crankshaft diameter.
Answer: b) AISI CIII2
a) 4.77 inches b) 3.77 inches
o Ans. b. C1112. This is a free-cutting steel with a higher sulfur c) 2.77 inches d) 1.77 inches
content for ease in machining

[Link] is an material; that is, its mechanical properties are Answer: a) Crankshaft Diameter = 4.77 inches
unique and independent in three mutually perpendicular directions—
longitudinal, radial, and tangential. Solution:
B
a) Isotopic b) Anisotropic
c) Orthotropic d) Any of these
A 6”
Answer: c) Orthotropic material Crankpin

103. A stepped torsion shaft has diameters of 16 mm and 12 mm and

a fillet radius of 2 mm. The shaft is subjected to a torque of 12.5 N- 11”
m. Find the maximum induced stress caused by the fillet. Consider a Crankshaft
stress concentration factor of 1.25.

a) 36.84 MPaa b) 46.05 MPa T  P  R   7500   6   45 000 in  lb

Solving for the torque,
c) 38.64 MPa d) 45.06 MPa

Answer: b) 46.05 MPa M   7500  11  82 500 in 

Solving for the bending moment,
Solution:
lb
Solving for the shaft diameter,

Solving for the average induced shear stress in the

shaft  16   13  16  13
16  12.5  2 2 2 2
16 T
s    36841422.01 Pa  36.84 D    M T    45000   82 500   4.77"
MPa s   4400 
s
d3
   0.012  3  s    
r = 2 mm

D = 16 mm d = 12 mm
[Link] principal raw materials used in steelmaking are iron ore, coal,
and . Answer: b) At high cutting speeds
a) Coke b) Limestone
c) Slag d) Flux

Answer: b) Limestone

[Link] steel part is heated to a temperature of 900–1150 degrees F in

an atmosphere of ammonia gas and dissociated ammonia for an 109. A parallel helical gear-set consists of a 19-tooth pinion driving a 57-
extended period of time that depends on the case depth desired. teeth gear. The pinion has a left-hand helix angle of 20 o, a normal
pressure angle of 14½o, and a normal diametal pitch of 10
a) Nitriding b) Carburizing teeth/inch. If the pinion is to transmit 50 Hp at a speed of 1750 rpm.
c) Case hardening d) Cyaniding Determine the center distance of the two gears.
Answer: a) Nitriding a) 2.02 inches b) 6.06 inches
c) 4.04 inches d) 2.06 inches
[Link] the Hp lost when a collar is loaded with 2000 lb, rotates
at 50 rpm, and has a coefficient of friction of 0.15. The outside Answer: c) 4.04 inches
diameter of the collar is 4 inches and the inside diameter is 2 inches.
Solution:

a) 0.7314 Hp b) 0.3714 Hp Pd
c) 0.4713 Hp d) 0.4371 Hp Tg
P   Tp
dn
cos 
D p cos Dg cos
Answer: b) 0.3714 Hp


Solution: Pitch diameter of the pinion,

Tp
Dp  19
 10 cos 20  2.02 inches
fHp
Tf n f W rf n 0.152000 lb1.56 inches50 rpm  0.3714 Pdn cos
63000  63000 
o
 63000 
 Tg 
   2.02 57   6.06 inches
DD
 3 3 
2  232  13 2 
f 2 3 ro ri 
r 2  r 2inches  3  1  1.56
 3 Pitch Diameter of the gear,
g p
 Tp   19 
r  
Where,  o i   
 Center-to-center distance,
Dp  Dg 2.02  6.06
108. The primary application of high-speed steels is to tools used for C   4.04 inches
the working of metals . 2 2

a) That are too hard b) at high cutting speeds

c) That are too soft d) at slow cutting speeds
[Link] gearing, this is the ratio of the arc of action to the circular pitch.
[Link] alloy (nickel, iron, chromium, cobalt is a non-magnetic, corrosion
a) Speed ratio b) Arc ratio resistant material suitable for sub-zero temperatures and temperatures up
c) Contact ratio d) Gear ratio to about 750 degrees F., provided that torsional stresses are kept below
75,000 pounds per square inch. It is precipitation-hardened to produce
Answer: c) Contact ratio hardnesses of 48 to 50 Rockwell C and is used in watch and instrument
springs.

111.A single square thread power screw is to raise a load of 70 kN. The
screw has a major diameter of 36 mm and a pitch of 6 mm. The
coefficient of thread friction and collar friction are 0.13 and 0.10
respectively. If the collar mean diameter is 90 mm and the screw
turns at 60 rpm, find the axial linear speed of the screw.

a) 5 mm/s b) 6 mm/s
c) 7 mm/s d) 5.5 mm/s

Answer: b) 6 mm/s

Solution: For the linear speed of the screw,

Vn = n (L) = (60 rpm)(6 mm/rev) = 360 mm/min = 6 mm/s

[Link] arms are usually of elliptical cross-section, the strength of

the arms should equal the strength of the shaft in
torsion.

a) Three-fourths b) One-half
c) Two-thirds d) One-fourth

Answer: a) Three-fourth
 a) Elinvar b) Monel Note: One-fourth of shaft diameter, as a guide in key selection for
c) Inconel d) Dynavar both square and flat rectangular keys.

Ans. Dynavar; source: Machinery’s handbook [Link] is the property of matter that causes it to resist any change in
its motion or state of rest?

a) Momentum b) Kinetic Energy

c) Inertia d) Section modulus

Answer: c) Inertia

[Link] is defined as the cutting time to reach a predetermined wear,

called the tool wear criterion.

[Link] ensure an adequate factor of safety in the design of a a) Wear duration b) Cycle time
shaft with standard keyway, the key width should be about: c) Tool life d) Life cycle

a) One half of the shaft diameter Answer: c) Tool life

b) One fourth of the shaft diameter
c) One eighth of the shaft diameter [Link] of the following G-codes refers to rapid traverse in CNC
d) One third of the shaft diameter machining?

Answer: b) One-fourth of the shaft diameter a) G00 b) G01

c) G02 d) G03
Answer: a) G00 a) 18 b) 16
c) 12 d) 10
[Link] acronym in CNC machining which means access of the machine
operator to insert machining instructions directly into the NC Answer: d) 10 percent
machine control system via push buttons, pressure pads, knobs, or
other arrangements. [Link] grades of stainless steels are nonmagnetic in the annealed
condition, although some may become slightly magnetic after cold
a) FMS b) FMC working?
c) CIM d) MDI
a) Ferritic grades b) Austenitic grades
Answer: d) MDI c) Martensitic grades d) Any of these
Note: MDI = manual data input Answer: b) Austenitic grades
[Link] steels (SAE Steels 1006, 1008, 1010, 1015) are the lowest
119. The variable polarity plasma arc (VPPA) process was developed carbon steels of the plain carbon type, and are selected where -
for welding metals that form an oxide skin, such as . is the primary requisite of the user.

a) Steel b) Copper similar classes of work in different plants.

c) Cast iron d) Aluminum b) Polishing is any operation performed with wheels having abrasive glued
to the working surfaces
Answer: d) Aluminum c) Buffing is done with wheels having the abrasive applied loosely
d) Polishing is not so harsh an operation as buffing, and it is commonly
120. Which of the following statements is NOT true? utilized to obtain very fine surfaces having a “grainless finish.”

a) The terms “polishing” and “buffing” are sometimes applied to Answer: d)

 a) Strength b) Cold formability
Note: Polishing is harsher than buffing.
c) Ductility d) Durability
[Link] the steel is strongly deoxidized by the addition of deoxidizing
Answer: b) Cold formability
elements, no gas is evolved, and the steel is technically called
because it lies quietly in the molds.
125. Steel is heated to a temperature above the critical range, after which
it is cooled in still air to produce a generally fine pearlite structure.
a) Quenched b) Annealed
The purpose is to promote uniformity of structure and properties
c) Killed d) Tempered
after a hot-working operation such as forging or extrusion. What was
the heat treatment involved?
Answer: c) Killed steel
a) Annealing b) Normalizing
[Link] steels generally contain at least per cent chromium, with or
c) Tempering d) Stress relieving
without other elements.
Answer: b) Normalizing

126. At certain speeds called the critical speeds, a rotating shaft will
become dynamically unstable and the resulting vibrations and
deflections can result in damage not only to the shaft but to the
machine of which it is a part. At what percentage of the critical
speed should a shaft be safely operated?

a) Plus or minus 20% b) Plus or minus 5 %

c) Plus or minus 10 % d) Any of these

Answer: a) Plus or minus 20 %

127. This is the most widely used of all spring materials for small springs
operating at temperatures up to about 250 degrees F. It is tough,
has a high tensile strength, and can withstand high stresses under
repeated loading.
a) Music wire
b) Hard drawn spring wire Ans. Electro-Discharge Machining (Source: Machinery’s Handbook)
c) Oil tempered spring wire
d) Stainless steel spring wire 129. In die casting accurate parts made of steel, what shrinkage allowance
in inches per inch is recommended?

Answer: a) 0.011 b) 0.022

c) 0.033 d) 0.044

Ans. 0.022. (Source: Machinery’s Handbook)

130. This are gears used to connect shafts that are non-intersecting and non-
128. It is an acronym in machining. This process uses an electrode to parallel. They are a cross between spriral bevel gears and worm gears.
remove metal from a workpiece by generating electric sparks
between conducting surfaces. a) Helical gears b) Hypoid gears
c) Planetary gears d) Bevel gears
a) MIG b) GMAW
c) EDM d) CNC Answer: b) Hypoid gears
 continuous flow of oil inside the chain loop evenly across the chain
131. This is a type of seal used where some form of relative motion width and directly at the slack strand.
occurs between rigid parts of an assembly.
a) Oil stream lubrication b) Bath lubrication
a) Gasket b) Distorted seal c) Drip lubrication d) Recirculated lubrication
c) Vibratory seal d) Dynamic seal
Answer: a) Oil stream lubrication
Answer: d) Dynamic seal

132. It is a lubrication for roller chains wherein the lubricant is supplied

by a circulating pump capable of supplying the chain drive with a

133. In manufacturing, this is the operation of cutting out flat area to

some desired shape and is usually the first step in a series of
operation.

a) Turning b) Facing
c) Blanking d) Finishing

Answer: c) Blanking

134. An M-code which generally refers to start spindle rotation in a

clockwise direction.

a) M03 b) M04
c) M05 d) M06

Ans. M03-spindle start in a clockwise rotation

135. A final operation to improve the polish of a metal and to bring out
the maximum luster

a) Finishing b) Surface grinding

c) Broaching d) Buffing

Answer: d) Buffing

136. Machining operations with the proper application of a cutting fluid

generally has the following attributes except:

a) Higher cutting speeds

b) Higher feed rates
c) Lengthened tool life
d) Higher cutting accuracy

Ans. D. The use of cutting fluids does not increase cutting

accuracy.
137. A material of construction (only developed commercially in the late 1940’s concurrently with zirconium) offers the unique combination of wide
 ranging corrosion resistance, low density, and high strength.

a) Tungsten b) Titanium a) Soldering b) Welding

c) Vanadium d) Molybdenum c) Brazing d) Any of these

Answer: b) Titanium Answer: c) Brazing

138. Which of the following is the lightest of all structural metals?

a) Aluminum b) Copper
c) Magnesium d) Manganese

Answer: c) Magnesium 143. In braking, the term backstop refers to a brake that is:

139. This process reduces internal stresses, caused by machining, cold a) Self locking in one direction
working, or welding, by heating the steel to a temperature below the b) Self energizing
critical range and holding it there long enough to equalize the c) Self locking in both directions
temperature throughout the piece. d) Any of these

a) Annealing b) Normalizing Ans. Self-locking in one direction only

c) Tempering d) Stress Relieving
144. How do you call a fixed crane consisting of a supported vertical
Answer: d) Stress Relieving member from which extends a horizontal swinging arm carrying a
trolley hoist or other hoisting mechanism?
140. A free-cutting steel has a higher content than comparable
carbon steels. a) Jib crane b) Gantry crane
c) Overhead crane d) Tower crane
a) Sulfur b) Cobalt
c) Nickel d) Chromium Ans. a) Jib crane

Answer: a) Sulfur 145. This iron is also known as a ductile cast iron. How do you call this
iron?
141. This property designates the steels resistance to the softening effect
of elevated temperature. a) Malleable iron b) Nodular cast iron
c) White cast iron d) Gray cast iron
a) Hot hardness b) Machinability
c) Toughness d) Elasticity Ans. b) Nodular cast iron is a ductile cast iron.

Answer: a) Hot hardness 146. It is the ability to deform plastically to compensate for irregularities
in bearing assembly. How do you call this?
142. Use of hard solders, silver solders and smelter solders which have
silver, copper, or nickel bases and have melting points above 800 a) Plasticity b) Conformability
degrees F is known as c) Embeddability d) Elasticity

Ans. b) Conformability
147. A material of construction (only developed commercially in the late 1940’s
 concurrently with zirconium) offers the unique combination of wide Free machining or free cutting carbon contains more sulfur than other
ranging corrosion resistance, low density, and high strength. steels.
a) Titanium b) Tungsten 152. Which of the following information is FALSE regarding steel that has
c) Vanadium d) Molybdenum increased carbon content?

Ans. b) Conformability a) Its strength is increased

b) Its BHN becomes greater
c) Its ductility is improved
d) Its % reduction or elongation is reduced

Ans. c) Its ductility is improved

148. Newton’s law of motion that describes that if a force acts to change The ductility of steel is reduced if its carbon content is increased.
the state of motion of the body, the body offers a resistance equal
and directly opposite to the force. 153. In manufacturing, what is the operation of cutting out flat area to
some desired shape and is usually the first step in a series of
a) Second law b) Third law operation?
c) First law d) Universal gravitation
a) Turning b) Blanking
Ans. b) Newton’s third law of motion: Action = Reaction c) Facing d) Finishing
149. These are steels most widely used of engineering materials. No Ans. b) Blanking
other material offers comparable versatility for product design.
154. This is a metal joining process which uses a non-ferrous filler
a) Wrought steels b) Low carbon steels metal with a melting point below that of the base metals but
c) Medium carbon steels d) Tool steels above 800F. How do you call this process?
Ans. a) Wrought steels a) Brazing b) Arc welding
c) Soldering d) Riveting
150. Which of the following steels does not readily respond to heat
treatment?
Ans. b) Blanking
a) SAE 1045 b) AISI 6150
155. Rivet holes are made usually inch larger in diameter than the
c) SAE 1020 d) SAE 1095
nominal diameter of the rivet.
Ans. Low carbon steels (0.3% C and lower) do not readily a) 1/8 b) 1/16
respond to heat treatment. c) ¼ d) 1/32
151. What is an element added to steel to improve its machinability?
Ans. b) 1/16
a) Carbon b) Sulfur
156. Which of the following equations/formulas does not belong to the
c) Cobalt d) Chromium
group?
Ans. b) Sulfur a) Lame’s equation b) Euler’s formula
c) J. B. Johnson’s equation d) Secant formula

Ans. a) Lame’s equation

 o Lame’s equation is an equation for a thick-walled pressure o The true stress-strain curve uses the actual area of the specimen
cylinder. The other 3 are for columns. and is therefore higher than the engineering curve which is
based on a constant (original) area of the specimen.
157. In CNC programming, which of the following G code commands is
for dwell or rest?
161. This is a hardening treatment for steels having low carbon content.
a) G01 b) G04
c) G03 d) G02 a) Tempering b) Case hardening
c) Normalizing d) Anodizing
Ans. b) G04
Ans. b) Case hardening
o G04 is for dwell or rest; G01 is for linear interpolation; G02 is for
circular interpolation CW; G03 is for circular interpolation CCW.

158. In CNC programming, which of the following M code commands is 162. What is a manufacturing process used for the production of
for a tool change? aluminum?

a) M06 b) M04 a) Forging b) Extrusion

c) M03 d) M10 c) Blow molding d) Injection molding

Ans. a) M06 Ans. b) Extrusion

o M06 is for a tool change; M03 is for spindle start CW; M04 is for 163. This refers to a loss of material from the interface of two metal
spindle start CCW; M10 is for chuck open. surfaces that are in intimate contact. How do you call this?

159. Which of the following is a material description referring to a) Interfacing b) Interference

unique properties in three mutually perpendicular planes? c) Wear d) Fretting corrosion

a) Isotropy b) Anisotropy Ans. d) Fretting corrosion

c) Orthotropy d) Isometry

164. This is a type of fit that requires heating the hub to expand its inside
Ans. c) Orthotropy diameter. What do you call this type of fit?

Ans. Example is wood which shows unique properties in the three a) Expansion fit b) Force fit
mutually perpendicular planes. c) Shrink fit d) Any of these

160. The true stress-strain curve in a stress-stress diagram appears to be: Ans. c) Shrink fit

a) Lower than the engineering stress-strain curve

b) Higher than the engineering stress-strain curve 165. AFBMA is an acronym for an association involved in what machine
c) The same as the engineering stress strain curve elements?
d) Symmetrical with the engineering stress-strain curve
a) Ball and roller bearings
Ans. b) Higher than the engineering stress-strain curve b) Journal bearings
c) Flat belts and other belt types
d) Any type of gears
Ans. a) Ball and roller bearings
 d) Elastic material bonded coupling
o AFBMA means Anti-Friction Bearing Manufacturers’ Association
and is concerned with rolling element bearings such as ball, Ans. c) Flexible Oldham coupling
roller, and needle bearings.

166. What is the general description for mild steel? 171. It is a machine member that supports another part that rotates,
slides, or oscillates in or on it.
a) Medium carbon steel b) Low carbon steel
c) High carbon steel d) Cold rolled steel a) Pulley b) Key
c) Bearing d) Shaft
Ans. Mild carbon steels are low carbon steels.
Ans. c) Bearing

167. Von Mises theory is the other term used for

a) Maximum principal stress theory 172. It is a bearing that permits constrained relative motion of rigid parts;
b) Octahedral shear-stress theory lubricant is generally inserted or supplied between the mating
c) Maximum shear-stress theory surfaces to reduce friction and wear, and to carry away the heat
d) Energy distortion theory generated.
Ans. b) octahedral shear-stress theory a) Sliding Contact Bearing
b) Rolling Contact Bearing
168. A type of key in which width and thickness are equal is called as: c) Thrust Bearing
d) Journal Bearing
a) Flat key b) Square key
c) Pin key d) Barth key Ans. a) Sliding Contact Bearing
Ans. b) Square key
173. These are surfaces that do not conform to each other very well as in
169. In the design of key, the typical hub lengths are in accordance with the rolling-element bearings.
the following relation where D is shaft diameter.
a) Conformal surfaces b) Non-conformal surfaces
a) 1.25D to 2.4D b) 0.5D to 1.25D c) Sliding surfaces d) Rolling surfaces
c) 2.4D to 3.5D d) Depends on shaft diameter
Ans. b) Non-conformal surfaces
Ans. a) 1.25D to 2.4D

174. The study of lubrication, friction, and wear of moving or stationary

170. A coupling that allows axial flexibility/movement in the operation. parts is known as:
Made of alternate bolting of steel, leather, fabric and/or plastic
material into two flanges. a) Lubrication b) Tribology
c) Hydrodynamics d) Hydrostatics
a) Flexible disk coupling
b) Flexible toroidal spring coupling Ans. b) Tribology
c) Flexible Oldham coupling
175. A bearing where surfaces are non-conformed and motion is primarily ring and inner ring.
rolling; it composed of rolling elements interposed between an outer
 a) Sliding-element bearing c) Centro is a point in one body about which another body actually
b) Rolling-element bearing turns.
c) Conformal surfaces bearing d) Centro is a point in one body about which another body tends to
d) Non-conformal surfaces bearing turn.

Ans. b) Rolling-element bearing Ans. b) Centro is a point in one body about which another
body does not rotate.

176. In a straight bevel gear, how do you call the angle between an
element on the pitch cone and an element on the face cone?
180. This is the most common work holding device of a shaper machine
a) Face angle b) Pitch angle with the base graduated in degrees that make it possible to swivel
c) Addendum angle d) Dedendum angle any angle. What is this working device?

a) Shaper vise
Ans. c) Addendum angle
b) Parallel bars and hold down bars
c) Lathe holder
177. It is a Grashof four-bar mechanism in which the shortest link is the
d) Swivel head
frame or fixed link and the other two cranks completely rotate with
their axes. How do you call this Grashof four-bar mechanism?
Ans. a) Shaper vise
a) Drag-link mechanism
b) Crank-rocker mechanism 181. This is a shaper operation, which is shaping the given stock and
c) Double-rocker mechanism having the excess material remain with a tolerable allowance for
d) Triple-rocker mechanism finishing. How do you call this operation?

Ans. a) Drag-link mechanism a) Roughing b) Finishing

c) Angular cutting d) Contouring
178. “For a planar four-bar linkage, the sum of the shortest and longest
lengths cannot be greater than the sum of the remaining two link Ans. a) Roughing
lengths if there is to be a continuous relative rotation between two
members.” How do you call the preceding statement? 182. How do you call a cutting tool that has two or more cutting edges as
a) Grubler’s Law b) Coriolli’s Law in drill presses and milling machine cutters?
c) Grashof’s Law d) Freudentein’s Law
a) Grinder b) Single-point cutting tool
Ans. c) Grashof’s Law c) Multi-point cutting tool d) Two point cutting tool

179. Which of the following is not true for an instant center or centro of
planar linkages? Ans. c) Multi-point cutting tool

a) Centro is a point common to two bodies having the same velocity 183. This is the trade name for a patented alloy made up chiefly of
in each. cobalt, chromium, and tungsten in varying proportions. What is this
b) Centro is a point in one body about which another body trade name?
does not rotate.

a) Stellite b) Carboloy
c) Stainless steel d) Copper
Ans. a) Stellite
184. It is called as the transformation of concepts and ideas into useful
machinery. What is this? Ans. c) Strain

a) Design b) Synthesis
c) Analysis d) Theorem 188. What is the combination of applied normal and shear stresses that
produces maximum principal normal stress or minimum principal
Ans. a) Design normal stress, with a third principal stress between or equivalent to
the extremes?
185. This is a combination of mechanisms and other components that
transforms, transmits, or uses energy, load, or motion for a specific a) Principal shear stress
purpose. How do you call this? b) Principal normal stress
c) Maximum shear stress
a) Mechanism b) Engine d) Bending and shear stresses
c) Machine d) Linkage
Ans. b) Principal normal stress
Ans. c) Machine
189. How do you call a load that is applied transversely to longitudinal
axis of member?

a) Combined loads b) Concentrated load

c) Bending load d) Distributed load

186. It is defined as synergistic collection of machine elements; Ans. c) Bending load

synergistic because as a design it represents an idea or concept
greater than the sum of the individual pats. What is this system? 190. What is the ability of the material to absorb energy up to fracture?

a) System of mechanisms a) Toughness b) Rigidity

b) Mechanical system c) Resilience d) Stiffness
c) Design system
d) Expert system Ans. a) Toughness

Ans. b) Mechanical system

191. What is the other term for the Maximum-Shear-Stress Theory, as a
failure prediction theory?
187. It may be defined as the displacement per length produced in a solid
and as the result of stress. How do you call this? a) von Mises criterion b) Tresca yield criterion
c) Coulomb-Mohr theory d) Modified Mohr theory
a) Deformation b) Elongation
c) Strain d) Stress Ans. b) Tresca yield criterion
192. It is a failure prediction theory, which states that a part subjected to whenever the maximum shear stress exceeds a critical value. How do you
any combination of loads will fail (by yielding or fracturing) call this failure prediction theory?
 195. How do call the speed at which a rotating shaft becomes dynamically
a) Distortion-energy theory unstable?
b) Maximum-shear-stress theory
c) Internal friction theory a) Normal speed b) Variable speed
d) Modified Mohr theory c) Critical speed d) Average speed

Ans. b) Maximum-shear-stress theory Ans. c) Critical speed

193. This is a theory in cyclic and impact loading, which states that 196. How do you call a ball bearing with race containing pronounced
damage at any stress level, is proportional to number of cycles. groove for rolling elements?
What is this theory commonly called?
a) Crown bearing b) Conrad bearing
a) Miner’s Rule c) Angular-contact bearing d) Cylindrical bearing
b) Paris Power Law
c) Goodman Rule Ans. b) Conrad bearing
d) Manson-Coffin Relationship

Ans. a) Miner’s Rule 197. This is a machining process for producing internal straight cylindrical
surface or profiles, with process characteristics and tooling similar to
194. This is a lubrication where the load-carrying surfaces of the bearing those for turning operations. What is this machining process?
are separated by a relatively thick film of lubricant, so as to prevent
metal-to-metal contact; and where the stability of the film can be a) Boring b) Drilling
explained by the laws of fluid mechanics. How do you call this type c) Reaming d) Milling
of lubrication?
Ans. a) Boring
a) Hydrostatic lubrication
b) Hydrodynamic lubrication 198. What is a set of specification for parts, materials, or processes
c) Elastohydrodynamic lubrication intended to achieve uniformity, efficiency, and a specified quality?
d) Boundary lubrication
a) Code b) Standard
Ans. b) Hydrodynamic lubrication c) Law d) Theorem

Ans. b) Standard

199. This is a set of specifications for the analysis, design, manufacture,

and construction of something; the purpose of which is to achieve a
specified degree of safety, efficiency, and performance or quality.
How do you call this set of specifications?

a) Code b) Standard
c) Law d) Theorem
Ans. a) Code
 Ans. c) Deviation
200. How do call the size to which limits or deviations is assigned and is
the same for both members of the fit; it is the exact theoretical size? 202. What is the difference between the maximum and minimum size
limits of a part?
a) Nominal size b) Basic size
c) Maximum size d) Minimum size a) Allowance b) Tolerance
c) Deviation d) Basic size
Ans. b) Basic size

201. What is the algebraic difference between a size and the Ans. b) Tolerance
corresponding basic size?

a) Tolerance b) Allowance 203. This is used either for very accurate angular measurements or for
c) Deviation d) Limit locating work at a given angle; is used together with precision gage
blocks. What is this?

a) Protractor b) Compound rest

c) Sine bar d) Micrometer

Ans. c) Sine bar