ESE 2022 Ace Academy Test 5 Solutions

TEST ID: 303
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ESE- 2022 (Prelims) - Offline Test Series Test- 5

MECHANICAL ENGINEERING
Manufacturing, Industrial and Maintenance Engineering

+ Mechatronics and Robotics _ SOLUTIONS
01. Ans: (d) because no matter how smooth the surfaces
Sol: Cubic Boron Nitride (cBN) is the second- are, there will be asperities on the surface at
hardest known substance (after diamond), the submicron level.
and has special applications, such as in
cutting tools and as abrasives in grinding 03. Ans: (c)
wheels. Sol: Comparison between servo-motors and
Glasses Contain a t least 50% silica; conventional motors
amorphous structures; Servomotors have the following advantages
Carbon nanotubes Unique crystalline form over the conventional large induction
of graphite, with high electrical and thermal motors:
conductivity; 1. They produce high torques at all
Sialon Consists of silicon nitrides and other speeds, including zero speed.
oxides and carbides; used as cutting tools 2. They accelerate or decelerate very
and feed tubes and linings for non-ferrous quickly.
metal casting 3. They have low rotor inertia; hence
their direction of the rotor can be
02. Ans: (c) changed very quickly.
Sol: Adhesive Wear: This type of wear occurs 4. They can bear high temperature at a
when two machine surfaces rub against lower speed or zero speed. Hence,
each other, with or without any lubricant they can dissipate heat quickly.
between them. Adhesive wear occurs
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04. Ans: (b) 08. Ans: (b)

Sol: A SCARA Robot structure consists of 4 Sol: Optical encoders are used for measuring
DOF – Revolute, Revolute, Prismatic, rotational speed to very high accuracy.
Revolute.
09. Ans: (b)
05. Ans: (b) Sol: Body and arm assembly section of the
Sol: At EOQ, robotic manipulator is used for positioning
Inventory carrying cost = Ordering cost of the objects in the robot work volume.
A
2000   500
Q 10. Ans: (a)
A Sol: To meet short range changes in demand of a
= No. of orders = 4
Q product, the following strategies can be
Hence, EOQ = 3 months sales. considered:
 Building and utilizing inventory
06. Ans: (c) through constant work force.
Sol: In die casting the hot liquid molten metal is  Varying the size of the work force.
poured into the cavity either by gravity  Overtime utilization.
force or by pressure force called as gravity
 Subcontracting.
die casting or pressure die casting.
 New investment increases capacity
and are long term in nature.
07. Ans: (b)
Sol: The Most Common NDT Methods
11. Ans: (d)
 Visual NDT (VT)
Sol: Spray transfer: Small, molten metal
 Ultrasonic NDT (UT)
droplets from the electrode are transferred
 Radiography NDT (RT)
to the weld area, at a rate of several hundred
 Eddy Current NDT (ET)
droplets per second; the transfer is spatter
 Magnetic Particle NDT (MT)
free and very stable. High DC currents and
 Acoustic Emission NDT (AE)
voltages and large-diameter electrodes are
 Dye Penetrant NDT (PT)
used, with argon or an argon-rich gas
 Leak Testing (LT)
mixture as the shielding gas. The average
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3 ME_Test-5_Solutions
current required in this process can be Address and data register store address and
reduced by using a pulsed arc, data during fetch cycle. The bus controller
superimposing high-amplitude pulses onto a drives the memory bus. The slave Program
low, steady current. The process can be counter holds the address like master
used in all welding positions. Program counter. The queue requests the
bus controller to fetch the code from the
12. Ans: (a) location whose address is within the slave
Sol: For failure mode, Program counter.
RPN = O  S  D
=521 14. Ans: (a)
= 10 Sol: Real-life applications of queuing theory
cover a wide range of applications, such as
13. Ans: (a) how to provide faster customer service,
Sol: Instruction Decoder or Microcode Engine: improve traffic flow, and efficiently ship
This is the main unit, which is responsible orders from a warehouse and the design of
for decoding the instruction. The telecommunications systems, from data
instructions (OPCODE) fetched from the networks to call centers. Queuing theory as
memory are placed in the IR. Once the an operations management technique is
OPCODE enters into the microprocessor, it commonly used to determine and streamline
must be decoded in order to generate staffing needs, scheduling and inventory,
control signals for ‘what to do next’. which helps improve overall customer
service.
Memory controller controls the memory.
The basic units of memory controller are: 15. Ans: (c)
 Address register Sol: Nose radius affects surface finish and tool-
 Data register tip strength. The smaller the nose radius
 Slave Program counter (meaning a sharp tool), the rougher the

surface finish of the workpiece and the
 Four-byte queue
lower the strength of the tool; a large nose
 Bus controller
radii can, however, lead to tool chatter.
16. Ans: (c) 20. Ans: (b)

Sol: A submersible pump with seeded faults in Sol: Arbor mounted milling cutters are:
the impeller was used for fault detection  Plain milling cutter / slab milling
using motor current signature analysis cutter
(MCSA).  Side face milling cutter
 Slitting saws
17. Ans: (a)  Special form cutters
Sol: Stroboscopes are used for the study of Shank mounted milling cutter
rotating, reciprocating, oscillating or  End mills
vibrating objects.  Four fluted end mill
 Two flute end mill
18. Ans: (a)
 Multi flute end mill
Sol: In a closed loop control system, the function
 Ball end mill
of the comparator block is to compare the
reference input with the present output.
21. Ans: (b)
Sol: Predictive and condition-based maintenance
19. Ans: (a)
(PdM/CbM) are both maintenance types
Sol: At EOQ,
that occur before breakdowns happen. As
Ordering cost = Holding cost
such, they are both forms of proactive
Total inventory cost = Ordering cost +
maintenance and are designed to increase
holding cost
reliability and decrease downtime.
Total inventory cos t
Ordering cost =
2
22. Ans: (c)
1000
= = Rs. 500 /order Sol: The number of bits (n) in an ADC register
2
determines the resolution and dynamic
D
Ordering cost =  Co
Q* range of an ADC.
10000
500   100
Q* 23. Ans: (c)
Q* = 2000 units/ year Sol:
24. Ans: (a) Survey of sales force, historical analogy

Sol: Total cost = F + v . x etc), whereas all qualitative techniques
For process I, TC = 50 + 3 50 = Rs. 200 (simple moving average method,
For process II, TC = 20 + 6 50 = Rs. 320 exponential smoothing etc) are suitable for
For process III, TC = 30 + 5 50 = Rs. 280 medium and long range forecasting.
Process I has lowest total cost so it should

be preferred. 29. Ans: (a)
Sol: When estimating the machining time ‘tm’ in
25. Ans: (a) a milling operation, it should be
Sol: remembered that the distance travelled by
 Lay is the direction of the pre domination the cutter would be larger than the length of
surface patterns, determined by the method the workpiece. This extended distance is
of machining. shown in given figure. In which it can be
 Different types of lays: vertical, horizontal, seen that the cutter travel distance is given
radial, cross hatched, circular, isotropic. by  w  a e d t  a e  .
26. Ans: (b) 30. Ans: (a)

Sol: FMECA methodology can be used To assist Sol:
in deciding alternative designs with high
reliability and safety potential during the
early stages of the design process.
27. Ans: (d)

Sol: PLC systems typically involve the handling
of circuitry operating at several different
voltage and current levels. As illustrated in Figure, a piezoelectric
accelerometer consists of a crystal in
28. Ans: (d) contact with a mass, supported in a housing
Sol: All quantitative techniques are well suited by a spring.
for short range planning (Delphi method,
31. Ans: (c)

=
100

200
1  0.5
Sol: Zmax = 3x1 + 5x2 1 10  103
x1 x 2 = 3 min
2x1 + x2  8   1
4 8
x1 x 33. Ans: (b)
6x1 + 8x2  30   2 1
5  15  Sol: In order to increase the resolution of
 
4
position measurement, two encoders are
x2
mounted in parallel and their signals are
8
7 passed through a XOR gate.
6
5
34. Ans: (a)
4
3 Sol: Regression analysis is used when the
2
(3.4, 1.2) demand trend equation is linearly increasing
1
or decreasing for forecasting.
x1
1 2 3 4 5
Zmax = 3x1 + 5x2 35. Ans: (c)

Z(4, 0) = 3  4 + 5 0 = 12 Sol: Swaging is a type of rotary forging in which
Z(3.4, 1.2) = 3  3.4 + 5 1.2 = 16.2 a solid rod or a tube is reduced in diameter
15 15 by the reciprocating radial movement of a
Z(0, ) = 3  0 + 5 = 18.75
4 4 set of two or four dies. The process is
Zmax = 18.75 suitable for producing short or long lengths
It is unique solution . of bar or tubing, with various internal or
external profiles.
32. Ans: (d)
Sol: Given: 36. Ans: (d)
L = 200 mm; B = 100 mm; Sol: The transfer function is defined as ratio of
f = 1 mm/double stroke output to input.
V = 10 m/min;
 1  M
B L
Time / cut 
f v
37. Ans: (c) relatively small sized problems. For ‘n’ jobs
Sol: The structural length index is the ratio of and ‘m’ machines there will be (n!) m
total length of the robot to the cube root of sequences of doing the job.
work volume.
43. Ans: (d)
38. Ans: (b) Sol: Comparison between direct extrusion and
Sol: PERT is used in the projects that are new, indirect extrusion:
non-repetitive or which involve research Sl. Forward or direct Backward or
and development whereas CPM is used for No. extrusion indirect extrusion
repetitive and standardized project. In this case the
The flow of metal is
metal flows in the
in the same direction
39. Ans: (a) 1. opposite direction
as the movement of
Sol: The ratio of the burnished area to the rough to the movement
ram.
area along the sheared edge increases with of ram.
increasing ductility of the sheet metal, and Low friction
decreases with increasing sheet thickness forces are
High friction forces
and clearance. 2. generated as the
must be overcome.
mass of material
40. Ans: (d) does not move.
Sol: A robot link controlled by a PID controller 25-30% less
does not have any steady state error but can extruding force
become unstable for high integral gains. High extrusion forces required as com-
required but pared to direct
3.
41. Ans: (a) mechanically simple extrusion. But
Sol: The jacobian matrix relates the end effector and uncomplicated. hollow ram
velocity and joint velocity. required limited
application.
42. Ans: (a) High scrap or Low scrap or
Sol: In large sized sequencing problem, use of 4. material waste about material waste,
Gantt chart becomes difficult so it used in 18-20% on an only 5-6% of billet
average. weight.  Obsolescence means the process of

becoming outdated and no longer used.
44. Ans: (b)
Sol: 48. Ans: (b)
Sol: Given, Thickness (t) = 8 mm
45. Ans: (b) Diameter (d) = 20 mm
Sol: Given data, Force (F) = 110 kN
Demand (d) = 50 jars per week, F = dt
Lead time (LT) = 2 weeks F 110  10 3 N
 
d = 3 jars per week, dt   20  8 mm 2
Acceptable risk = 10 %,  218 .83 MPa  219 MPa
so service level is 90%
Reorder point (ROP) = d  LT  zd LT 49. Ans: (c)
Sol: A variable-reluctance stepper motor consists
 50  2  1.28  3  2
of a single or several stacks of stators and
= 100 + 5.43
rotors, stators have a common frame and
= 105.43  106 units
rotors have a common shaft a
46 Ans: (d)
50. Ans: (a)
Sol: Computer-aided part programming involves
Sol: Mean arrival rate () = 6 jobs every 30 min
special symbolic programming languages
30
that determine such coordinate points as Mean service time () = = 7.5 /30 min
4
corners, edges, and surfaces of the part.
 6
   0.8
 7.5
47. Ans: (b)
Expected number of jobs in the system
Sol:
 0.8
 Inspection and tendering cost are a type of (Ls) =  4
1   1  0.8
ordering cost.
 Depreciation, obsolescence cost and
insurance cost are a type of holding cost.
51. Ans: (d) 53. Ans: (b)

Sol: The program contains the following Sol:
instructions and commands: Completion
Process Completion Due
 Geometric instructions pertain to Job time – Due
time time date
relative movements between the tool date
B 8 8 32 – 24
and the workpiece.
A 10 18 34 – 16
 Processing instructions concern spindle
D 6 24 36 –12
speeds, feeds, cutting tools, cutting
F 12 36 41 –5
fluids, and so on.
C 16 52 46 6
 Travel instructions pertain to the type of
E 18 70 64 6
interpolation and to the speed of
66
movement of the tool or the worktable.
Average number of tardiness = 2
6
 Switching instructions concern the on– Positive lateness is tardiness and late jobs
off position for coolant supplies, are C & E.
direction or lack of spindle rotation, tool
changes, work piece feeding, clamping, 54. Ans: (d)
and so on. Sol:
 The erosion takes place on both the tool and
52. Ans: (c) the workpiece but the tool is eroded much
Sol: less in comparison to the workpiece.
 Increasing the stiffness of the spring  Gap control in EDM is affected through a
increases the natural frequency of the servo system which correctly locates the
system. tool in relation to the workpiece surface,
 Increasing the mass reduces the natural maintains constant gap throughout the
frequency of the system. operation, senses the changes in the gap and
corrects them immediately. A short-circuit
across the gap causes the servo to reverse
the motion of the tool until the correct gap
is established. Servo system may be
electrical or hydraulic type. Electro 59. Ans: (d)

hydraulic servo control is preferred. Sol: Given data,
 Tool or electrode in EDM is made from Optimistic time (top) = 10 days
brass or copper although electrodes (tool) of Most likely time (tm) = 15 days
tungsten, graphite, steel and silver alloys are Pessimistic time (tp) = 22 days
also used.  t p  t op
2
  22  10 
2
Variance =      4
 6   6 
55. Ans: (c)
Sol: The DH parameters consist of 4 parameters 60. Ans: (c)
(transformations). Sol: Variable Reluctance Stepper Motor has
wound stator poles but the rotor poles are
56. Ans: (c) made of a ferromagnetic material.
Sol: Planning, Routing, Scheduling and loading
are the main tasks in the production 61. Ans: (b)
planning while, dispatching, follow up,
inspection and corrective actions are the 62. Ans: (c)
production control practices.
Time  remaining
Sol: C.R =
work  remaining
57. Ans. (d) If C.R < 1, the job is behind schedule,
Sol: The number of impacts on the work piece If C.R = 1, the job is on Schedule
by abrasive grits in each cycle is dependent If C.R > 1, the job is ahead of schedule.
upon the diameter of the abrasive grit. In connection with scheduling if the critical
ratio for a job is less than unity, it indicates
58. Ans: (c) job completed after the due date with
Sol: Workspace of spherical coordinate robot tardiness.
will be the volume swept between two
partial spheres. 63. Ans: (d)
64. Ans: (c)
65. Ans: (b) The advantage of such a maintenance

technique is that the machine’s condition is
66. Ans: (c) known to the operator at any time it is
Sol: needed, which allows the operator to
 Shell moulding is used for thin sections, determine whether the machine needs to be
sharp corners and components having small fixed or not.
projections which are not possible by Worldwide, it has been reported that over an
normal sand casting. extended time, predictive maintenance is
 In shell moulding the thickness of the more economical than preventive
component will depend on the time with maintenance, though it is initially expensive
which the component is in contact with the because of the additional requirement of an
mould. instrumentation system.
67. Ans: (b) 69. Ans: (b)

Sol: Die shift: Die shift is caused by Sol: Servo and proportional control valves are
misalignment between the top and bottom both infinite position valves which give a
forging dies. This may be caused due to valve spool displacement proportional to the
loose wedges. current supplied to a solenoid. Basically,
Fins and rags: Fin and rags are small servo valves have a torque motor to move
projections or loose metal driven into the the spool within a valve (Figure). By
surface of the forging. varying the current supplied to the torque
Hence given all three statements are correct. motor, an armature is deflected and this
moves the spool in the valve and hence
68. Ans: (a) gives a flow related to the current. Servo
Sol: Predictive maintenance has the additional valves are high precision and costly and
requirement the instrumentation system generally used in a closed-loop control
mentioned earlier—so at the time the system.
machine is installed there is an additional
expenditure for this instrumentation system.
 In resistance welding process the heat is

required to generate at the joint to melt and
produce the joint. This heat is generated due
to the presence of contact resistance
between the joining surface or also called as
faying surfaces or asperities between faying
surfaces.
Fig: The basic form of a servo valve.

72. Ans: (a)
Sol: Oil Sampling Technique: The wear debris
Proportional control valves are less
that contaminates the lubricating oil is
expensive and basically have the spool
usually analyzed by collecting the oil from a
position directly controlled by the size of
few particular locations in the lubricating
the current to the valve solenoid. They are
system of the machine. Since the wear
often used in open-loop control systems.
debris can be of submicron sizes, care has to
be taken regarding the cleanliness of the oil
70. Ans: (a)
collecting and storage system.
Sol: As the project length is determined by the
The locations from which the oil is
critical activities only so there is no use of
collected must also represent the true
crashing non-critical activities because that
dynamics of the wear mechanism.
would not reduce the project duration.
Therefore, oil must be collected when the
engine is running because, due to gravity,
71. Ans: (d)
all the debris would be deposited in the
Sol:
bottom of the lubricating sump if samples
 In resistance welding process the heat is
are taken when the machine is idle.
required to generate at the joint to melt and
produce the joint. This heat is generated due
to the presence of contact resistance
between the joining surface or also called as
faying surfaces or asperities between faying
surfaces.
73. Ans: (c) 75. Ans: (d)

Sol: The function of the ALU constituent part of Sol: An inductive proximity switch consists of a
a micro processor. coil wound round a core. It can only be used
 Arithmetic and logic unit (ALU) The for the detection of metal objects and is best
arithmetic and logic unit is responsible with ferrous metals. Hence given statement
for performing the data manipulation. (I) is incorrect.
 Registers One form of capacitive proximity sensor
 Control unit consists of a single capacitor plate probe
Accumulator register: The accumulator with the other plate being formed by the
register (A) is where data for an input to the object, which has to be metallic and earthed
arithmetic and logic unit is temporarily (Figure). As the object approaches so the
stored. ‘plate separation’ of the capacitor changes,
Status register, or condition code registeror becoming significant and detectable when
flag register: This contains information the object is close to the probe.
concerning the result of the latest process Hence given Statement (II) is correct. So
carried out in the arithmetic and logic unit. option (d) is correct.
It contains individual bits with each bit Coaxial cable
having special significance. The bits are

called flags. Guard ring
Hence Statement (I) is correct and

Statement (II) is incorrect. So option (c) is
Object
correct.
74. Ans: (d)

Sol: Aggregate planning is rooted in the
manufacturing sector, but many of its
concepts apply to service industries, too.
Hence, assertion is wrong.
Services are perishable. This implies that
they cannot be inventoried.

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TEST ID: 303

ESE- 2022 (Prelims) - Offline Test Series Test- 5

Manufacturing, Industrial and Maintenance Engineering

04. Ans: (b) 08. Ans: (b)

 Data register tip strength. The smaller the nose radius

 Slave Program counter (meaning a sharp tool), the rougher the

16. Ans: (c) 20. Ans: (b)

24. Ans: (a) Survey of sales force, historical analogy

Process I has lowest total cost so it should

25. Ans: (a) a milling operation, it should be

Sol: remembered that the distance travelled by

of machining. shown in given figure. In which it can be

radial, cross hatched, circular, isotropic. by  w  a e d t  a e  .

26. Ans: (b) 30. Ans: (a)

27. Ans: (d)

31. Ans: (c)

Zmax = 3x1 + 5x2 35. Ans: (c)

average. weight.  Obsolescence means the process of

51. Ans: (d) 53. Ans: (b)

electrical or hydraulic type. Electro 59. Ans: (d)

64. Ans: (c)

65. Ans: (b) The advantage of such a maintenance

67. Ans: (b) 69. Ans: (b)

 In resistance welding process the heat is

Fig: The basic form of a servo valve.

73. Ans: (c) 75. Ans: (d)

having special significance. The bits are

Hence Statement (I) is correct and

74. Ans: (d)

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