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Tuesday 28 June 2016

Material science

UPSC syllabus
Engineering materials:
basic concepts of structure of solids; common ferrous  and non ferrous materials and their applications; heat treatment of steels; non metals--plastics, ceramics, composite materials and nano materials
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My commentary
Scoring topic. Straightforward concepts. Fairly easy to understand.
Challenge is to get the right source and put in the time required to get it once.
Next challenge is to revise, so as to not get confused between the numerous materials and processes
All said and done, it is a topic that brings good returns.
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Now topicwise categorization.

First some general notes in QnA format. These are mostly ESE questions arranged topicwise.
Materials notes qna

Crystals, lattices, Miller indices
CSE2009A1c20 solved
CSE2008A1d20 solved
CSE2007A1d20 solved
CSE2005A1d20 solved
Crystal defects
CSE2011A4c15 solved
Grain size
CSE2007A4a15 unsolved -- cant find exact answer
Fatigue, creep, aging
CSE2005A4d10 solved
CSE2003A4b15 solved
CSE2004A4d15 unsolved -- refer Amitabha Ghosh

Fe-C diagram
CSE2003A4a15 solved
CSE2012A1c12 solved
CSE2010A1d12 solved
CSE2010A4c20 solved

TTT diagram
CSE2008A1d10 solved 2003A4c15 solved
CSE2003A4d15 solved
CSE2008A4b15 solved

Heat treatment/Hardening
CSE2008A4a30 solved
CSE2009A4c20 solved
CSE2007A4d20 unsolved
CSE2004A4c15 solved

Steels
CSE2012A3c10 solved --refer to below
CSE2011A1f10 unsolved -- refer to Qs below
CSE2006A1d20 solved
CSE2006A4a30 solved

Testing
CSE2011A1e10 solved
CSE2011A1d10 solved

Non ferrous alloys
CSE2010A4a20 solved -- babbitts
CSE2005A4c10 solved -- aluminum
CSE2003A1d20 solved -- misc

Ceramics
CSE2011A4d15 solved and more

Composites
CSE2008A4c15 solved
CSE2006A4b30 solved
CSE2005A4b20 solved
CSE2004A4b15 solved

Polymers
CSE2012A2c10 solved
CSE2007A4c10 solved
CSE2010A4b20 solved

There are many sources for this topic.. Kalpakjian is most often recommended. But mostly after a couple of years out of college, it is difficult to get a hold of one..
Personally, I used Amitabha Ghosh, Swadesh Singh(has many errors, but something better than nothing), ignout notes for random topics like plastics/composites/jigs fixtures etc
Most of all, for Crystals, Fe-C diagram, heat treatment etc I found deGarmo very good.. excellent language, good diagrams.. highly recommended.. selective reading.. whole book is vast..

That's all folks.

Monday 27 June 2016

Manufacturing Science

UPSC syllabus for Mfg Sci
Manufacturing process: Machine tool engineering--Merchant's force analysis, Taylor's tool life equation; Conventional machining; NC and CNC machining process; jigs and fixtures
Non-conventional machining(ncm/ntm) -- EDM, ECM, ultrasonic, water jet machining etc; application of lasers and plasmas; energy rate calculations
Forming and welding processes--standard processes
Metrology--concept of fits and tolerances; tools and gauges; comparators; inspection of length, position, profile and surface finish
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My commentary:
The above syllabus is quite misleading.. Merchant, Taylor is only straightforward part. NC/CNC is a bit open ended, but still manageable. Jigs and fixtures topic is wide open. There are ignou notes for jigs and fixtures but the questions in exam seldom match this material.
NCM is alright.. one should not sweat too much over it. There is the book Manufacturing Science by Mr Amitabha Ghosh which is good.. a diagram, basic technical details, equations if any, advantages and limitations for each process.. that is it.. no more..
Not sure what "Energy rate calculations" means.. there is not much material on it..

Forming and welding processes-- there is forging, rolling, various types of welding-- theoretical questions and numericals(that are difficult to make sense). So, this short mention in syllabus is an atrocity. Put some extra time into understanding this section. I cant suggest any particular book, as I would use googlebooks search for each question and prepare in piecemeal fashion..

Metrology-- one section where one can hit ball out of stadium. Sure shot marks, if prepared well.
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Now some theory pages, some solved questions under topic categorization of my own..
I have also placed some questions from ESE and IFoS in sub topics without mentioning year etc.

A complete set of notes on manufacturing science: Mfg theory [7.5MB]

Casting theory
More on casting
CSE2011B5C10 solved

Forming
HERF
CSE2005B5b20 solved
Forging
CSE2007B6b30 solved
CSE2011B6c10 solved
CSE2009B7a10 solved
More on forging
Forging numericals
Rolling:
CSE2012B8b15 solved
CSE2006B8a20 solved
Tube mfg
CSE2010B6b30 unsolved
CSE2008B6b10 solved
Extrusion
CSE2012B8a15 solved
More on extrusion
Punching
CSE2011B5a10 solved

Welding
DC welding
CSE2008B6a30 solved
Gas welding
CSE2010B6a30 solved
CSE2011B7b20 solved
Flame cutting note
GTAW
CSE2009B7a10b unsolved
SMAW SAW
CSE2012B7b20 unsolved
Laser/plasma welding
CSE2007B6a30 solved
More on welding
Weld defects
per cent C equivalent

Jigs and fixtures note
CSE2012B5b12 solved
CSE2005B8b20 solved
321 location
CSE2009B8a20 solved
CSE2007B5a20 solved

Cutting:
Chip formation
CSE2008B5a20 solved
CSE2006B5b20 solved
Cutting ratio
CSE2009B5a20 solved
Turning tool
CSE2003B5b20 solved
Merchant
CSE2006B5a20 solved
CSE2005B5a20 solved
CSE2003B6a30 solved
CSE2003B6b30 solved
Tool life/Taylor
CSE2012B5a12 solved 2011B6d10 solved
CSE2010B5c12 solved
CSE2003B5a20 solved
Tool material
CSE2007B8a30 solved
More on cutting

Drilling:
CSE2012B6a10 solved   next page
CSE2006B6a30 solved

Milling:
CSE2009B5b20 solved
CSE2008B8a30 solved

Grinding:
CSE2012B6a20a    CSE2012B6a20b solved
More on grinding




Tool materials
CSE2007A4b15 solved
CSE2008A1d10 solved

Metrology
Fits and tolerances
CSE2011B5b10 solved CSE2011B5d10 solved
CSE2010B5d12 solved
CSE2007B7a30 solved
CSE2009B6a20 solved
CSE2005B8a20 solved
CSE2013B5e10 solved
CSE2012B5c12 solved
Metrology theory

NC machines
CSE2008B5b20 solved
CSE2011B6b10 solved
CSE2010B7a30 solved
CSE2005B6b15 solved
CSE2004B6a20 solved
CSE2011B7c10
CSE2005B6c15
CSE2004B6a10
CSE2012B8c10
CNC machines theory

Programming
CSE2007B5d20
CSE2006B8c20
CSE2005B8c20
CSE2004B8b30

Non Conventional Machining
EDM theory
CSE2012B6b20 solved
CSE2009B8a15 solved
CSE2006B6b30 solved
CSE2004B6b30 solved
AJM theory
CSE2011B5e10 solved
CSE2008B6b30 solved
ECM
CSE2011B8b20 solved CSE2008B6b5 solved
CSE2005B6a30 solved
USM
CSE2007B5b20 solved
PAM EBM LBM theory

Sunday 26 June 2016

Industrial Engg

Industrial engineering is a scoring topic, as it is largely procedural. One has to know the flowchart of solving certain types of questions, then on it is simply clockwork, easy marks. But, the challenge, is the large number of types of questions.
The syllabus given by UPSC for this topic is as follows:

Manufacturing management:
System Design: factory location--simple OR models; plant layout-method based; applications of engineering economic analysis and break even analysis for product selection, process selection and capacity planning; predetermined time standards
[decoded: location, LP, break even, PTS]
System planning: forecasting methods based on regression and decomposition, design and balancing of multimodel and stochastic assembly lines; inventory management--probabilistic inventory models for order time and order quantity determination;JIT systems; strategic sourcing, managing inter plant logistics
[decoded: forecasting, line balancing, queuing theory, EOQ, JIT, TSP]
System operations and control: scheduling algorithms for job shops; applications of statistical methods for product and process quality control-applications of control charts for mean, range, %defective, defects per unit; quality cost systems; management of resources, organization and risks in projects
[decoded: job sequencing, SPC, PERT]
System improvement: implementation of systems such as total quality management, developing and managing flexible, lean and agile organizations
[decoded: TQM, TPS, kanban, lean mfg]

Following above sequence of topics for study is cumbersome. So, better catch easy topics and move towards more abstract and rigorous topics.


Probabilistic analysis
CSE2011B6e10 solved CSE2010B5b12 solved
CSE2011B6e10 solved CSE2010B5b12 solved

Breakeven analysis
CSE2006B5c20 solved
CSE2004B5c20 solved
CSE2008B5c20 solved

LP
CSE2004B8a30 solved
CSE2014B5d10 solved
CSE2003B8b30 solved

Simplex
CSE2005B7c20 unsolved
This was the last time a question appeared on simplex. Then after 10 years in 2015 simplex re appeared in CSE. Beware and if you want to score 250+, dont leave out topics, like me


Inventory theory
CSE2008B8c25 solved
CSE2009B6b20 solved
CSE2013B7c15 unsolved

Inventory ABC analysis
CSE2007B5c20 solved

Forecasting theory
CSE2009B7c20 solved
CSE2008B7a30 solved
CSE2005B7b10 solved
CSE2013B6d20 solved
CSE2009B5c20 solved

Job sequencing theory
CSE2009B8c20 solved
CSE2012B6c10 solved
CSE2007B7a30 unsolved   -- too long, time killer
CSE2005B5d20 solved
CSE2004B7b30 solved

Queuing layout and line balancing theory
Queuing
CSE2004B5d20 solved
Layout
CSE2009B6c20 solved
Workcenter grouping/line balancing
CSE2012B5d12 solved
CSE2013B7a25 solved

Work study theory
CSE2012B5e12, CSE2012B8b10, CSE2010B5a12
CSE2011B7a30 solved
CSE2007B8b30 solved
CSE2006B5d20 solved
CSE2003B5d20 solved
CSE2005B5c20 unsolved, refer theory

PERT CPM theory
CSE2009B7b20 solved
CSE2008B7b30 solved
CSE2007B7b30 unsolved
CSE2006B7b30 solved

SQC theory
Quality cost
CSE2009B5d8 solved
CSE2004B7a10 solved
SPC
CSE2012B7a5 solved
CSE2010B7b30 unsolved
CSE2013B6b10 unsolved
CSE2006B8b20 solved
CSE2008B5d20 unsolved
CSE2013B8a20 solved
CSE2004B7a20 unsolved
CSE2003B8a30 unsolved
CSE2005B7a30 unsolved

Value analysis
CSE2003B5c20 solved
Automation theory
CSE2004B5b20 solved
Kanban theory
JIT TPS lean ops
CSE2010B8a30 solved
CSE2013B5a10solved
CSE2014B8a20 solved
CSE2012B7a15 solved

TQM
CSE2010B5e12 solved

TSP theory
CSE2010B8b30 unsolved
CSE2003B7b30 unsolved

Assignment problems
CSE2006B7a30 solved
CSE2011B8a30 solved

That's all folks..
Google drive link to folder containing all of the above files: IPM

Mech Engg

I have already written much about nature of mechanical engineering as an optional, book list etc. (On Mech for CSE) At risk of repeating myself, I want to present here, how I went about building up my material for the subject.
It was an evolution. Step1 was as soon as I came to Delhi. I bought a booklet with all previous year questions(20 years) on Mech. Then, I thought of mapping them out. So, I made MS-Word pages with yearwise Q numbers 1-8. Then in each box, I would write down topic name of that question. Then I color coded, to see if there is a pattern. Then, I realized this is turning out to be a kindergarten exercise.(took 10 days) But, it helped me in getting a picture and moving to next stage.
Step2, I started writing down questions on A4 sheets, 1 page 1 question, using ref no. like 2008A1b20 that would mean year 2008 Section A Qno. 1(b) of  20 marks. Further I started grouping these questions into major topic folders.(took about 15 days) When this was done for 10 years 2003-2013, I then started trying to solve them.
So, this was my ground work. I would take a look at the questions, then go read the book, come back to questions and try to solve them, realize I have read irrelevant sections, search for reading material on net, search the question itself on net and then try to solve as many questions as I can. This step took me forever. I have not completely solved all questions till date.
Step3, evolved out of step2, though without end of step2. I started segregating questions within a topic, according to subtopic. Then I realized that there are certain types of questions and certain subtopics which are often asked. This gave speed to my prep and also confidence that "itna kar liya, to kuch to milega".
That is it. I have lot of topicwise books on mech, but backbone of my prep, was these stacks of sheet tied together topicwise and collected subtopicwise, which would help me revise the subject with ease.

When I was asked for these notes/approach by my fellow warriors, for a second, I had hesitated. But I would then give it them. I must say, till now whoever has taken these notes and appeared for mains, have scored more than me in Mech :) (shameless smile) But they have returned the favor by pouring best wishes on me. I thank them, and as promised, would like to share all the notes(however incomplete they are) here. Please bear with the unsolved questions. The least you get is organized structure, the best is a correctly solved question :D

Paper1
SOM strength of materials -- upload complete
Theory of machines -- upload complete
Machine Design -- is not a heavy topic in CSE, so I have clubbed it with TOM
Industrial Engineering -- upload complete
Materials  --upload complete
Manufacturing Science  -- upload complete

Paper2
BThm Basic thermodynamics -- upload complete
Heat mass transfer -- upload complete
IC engines 1 , IC Engines 2 -- upload complete
RAC refrigeration and air conditioning,    RAC part 2 -- upload complete
Gas Dynamics and Fluid dynamics -- upload complete
Powerplants, Steam generation, Fans blowers -- upload complete

Thursday 9 June 2016

Humpty dumpty

IT is weird thing...being placed up on a pedestal so quickly... One day you are an ordinary person, just like most of the people on earth struggling to achieve their goal.. Some eking a living to feed/clothe/shelter themselves and their kids, some for a better way of life, etc. There are some who also are struggling to bring justice to others. I do not consider myselves worthy of putting myself in any of these categories right now. I still spend money earned by my father, burden my mother with work, while I sit spinning ideas about what I would want to do in life further on. Yet, there are many who shower praise on me as if I have brought liberation to souls of my parents and freedom to our nation. I feel like Obama being given the Nobel peace prize at very beginning of his term. I feel torn inside. On one hand, I feel that I should be self-effacing as advised by ancient Chinese wisdom, to keep myself rooted to ground. But I can't shun people away, and have to listen patiently to my praises. Humbly accepting their blessings and words of caution about future endeavours. I feel glad that I am approaching middle age, so have my head balanced on my shoulders, while I see some young ones mouthing off about their success "despite" their ignorant parents. I wish I could have a word with them, like I would with my sibling and advise them to stay clear of the wave of pride that sweeps us far away from the people and conditions that made us, into an island of delusion.
I suppose that is a trend. You give a person too much success too soon and one starts believing that it is destiny. The odd victories over fate just baffle logic of most sane person.  Then as the cannon balls of sycophancy crumble the walls of humility, ego takes over and blinds a person.
I hope that I don't give in to praises and start climbing the wall, only to fall.
I wish to be at the foundation. I remember when I was at crossroads, deciding about quitting my job and preparing for civil services exam full time, I remembered a lesson from Class VIII Hindi textbook. It was "neev ki eent" meaning brick in foundation. So, all that time spent on languages in school does have meaning in life. I was inspired by that idea then and even now. I don't want to become that "swarn kalash" the shining finial at the top, but the unseen load bearing brick at the bottom.
So, I accept with great humility all the blessings and well wishes of people and pray that I am reminded of my place, by my conscience, even if people fail to do so.
Now, another thing is that I do not wish to take moral high ground over those who wish to celebrate their success. Cheers to them, but a word of caution from Mr Humpty Dumpty.

Saturday 4 June 2016

Essay writing

This post is on writing essay for the CSE mains exam. First, my credentials. I scored in 90s in essay paper in 2014 mains and 138 in 2015 mains. I have heard that essay is very unpredictable and one cannot tell if they will score poorly or not. I won't make generalizations by saying that one can make predictions, but will speak on my experience.
Last year(2014), I wrote an essay on competition and the other on Olympics/sports topic. In the first one I started off poorly. My introduction was based on natural selection trying to show that competition seems to be law of nature, but it was a lopsided intro. I went on to discuss positives and negatives of competition. Points were quite generic. By end of the essay, I realized that I had already performed way below my potential. Next I took up on sports essay and went for all angles that are relevant and added latest points with examples. So, I knew that overall my marks would not be outstanding. Marks were as expected. So, what went wrong in first essay?
1. I had joined a certain essay test series where the instructor was stubborn about people following his method of rough work and would not even go thru the points. So, I ended up getting confused in the hall, doubting the efficacy of his method and ended up with a big mess of rough work, with haphazard layout. So, lesson learnt-- preserve your own genius and dont let methods of anyone take over your original style. If something helps you then take it up, but if you feel it doesnt suit you, immediately drop it and move on.
2. I had completely missed the angle of cooperation. Opposite of competition is cooperation. It is also seen in nature, most among insects and sometimes even among humans :) bringing great results. Missing this angle, I feel made my essay bit mediocre. So, lesson learnt-- think deep, read more. Reading more of various ideas, cultivating them, thinking on them helps generate that salad material in one's mind. This can then be used to decorate the essay and make it palatable.
3. There was no flow in my essay. I made an intro without thinking how I would transition into the essay from there. So, it seemed like break dance. Some intro, then jump to some random idea and then into a mediocre framework of +/- of competition. Frankly, when I finished my paper and re read my essay, I was disappointed in myself. Lesson learnt, plan well on the mega framework you are going to work on and the flow you are going to create in the essay.

With these lessons learnt and some more planning, I was ready to take on essay paper in 2015. No essay test series. All I did was go thru previous year generic topics and essay test papers of various classes in market. I used to think on the mega framework and the flow of the essay and leave it.
Finally, I wrote only 2 essays that too 2 weeks before exam, just to test my writing speed, paragraph planning and ability to use examples in points.

So, having gone through bit of what not to do, lets see what can be done in essay paper.
1.Choice of topics: always choose homeground. Dont become generic. I never thought I would write an essay on philosophical topic, but I did this year. I wrote on Lending hands better than giving dole.
I could connect with topic instantly and had flood of ideas that I could rope in. Other topics were also great, but trusting gut is important. Other topic I chose was technology, with a degree in tech, natural inclination. But other topics seemed challenging/open ended, so tech seemed safer all the more.
2.Time division: Now with 5-10 mins gone in deciding topic, we are left with roughly 1.5 hours for each topic. Standard rule, do not begin writing essay till end of half an hour of planning. It is better you exhaust time to think and then write than come up with an idea later with no space to insert.
3.Megaframework: This is the larger angle you are going to use to approach the essay topic. Usually it involves breaking essay topic line into 2-3 parts and then these become major blocks in the essay. Under these you create a tree of different points, subpoints and then attach leaves of examples to substantiate.
Ex. In "lending hands..." there was no way of breaking topic in 2-3 parts, so I had to go for megaframework with multiple angles. So, first historical angle.. Indian history is a history of resilience and self reliance. During struggle for independence, we fought for freedom from British and social evils. In society, Gandhiji did not give out doles, but gave helping hand, made people self reliant. After independence also, India charted a path where we never put out our hand for doles from other countries and remained non-aligned. For our farmers, we did not handout freebies and make them state-dependent, we went for land reforms and gave them way towards self dependent life.
[So, historical angle is the big branch and the above are points and examples are leaves. Each of these points make a healthy paragraph.]
Political angle: Went for Panchayati raj which is again story of helping people and not handing out doles. Federal structure and local governance system shows how helping people is better than mere handing out funds. So, need to devolve functions and functionaries too, making system truly democratic.
Development angle: Cooperative movement in different sectors like milk and green revolution are stories of people prospering with a little help given to them. Hand they been given doles, they would not have realized their potential. SHGs are growing steadily across India, showing how with some help from state, people on their own are building livelihoods without the need to look to state for alms.
Economic angle: Nobel laureate Amartya Sen has already pointed out capabilities approach. With programs like Make in India, Skill India, MUDRA, PMJDY India is charting a path towards making people self dependent. The economic survey too speaks of rationalizing subsidies and investing in people, by helping them become capable and not mere beneficiaries of the state.
International angle: India also believes in helping out other developing countries by making them more capable. Programs like ITEC have been helping many developing countries in our neighbourhood and Africa achieve technical and educational progress through training of personnel and investment in infra in these areas. Collaborations like IOR-ARC, FIPIC, 3rd IAFS have led to India helping countries with tangible resource development on the ground, without the side effects like those from investments from China in mining. Furthermore, even in COP21 and SDGs the concept of building capabilities is clear, as just handing out doles under Kyoto protocol has not helped the situation at all.
Philosophical angle: Reserved for conclusion.
4.Intro, conclusion:I have seen in many Yojana articles by editors that they use an incident based intro and have a conclusion that comes full circle to connect with the intro.
This is an awesome technique as it gives that "ting" effect when you connect intro and conclusion.
Also, this way one does not have to go for quotes. Quotes are big responsibility. Quote has to be relevant, one who said should preferably be a decent guy and an Indian. Also, mistake in quotes dont look good, as you are then putting wrong words in mouth of some great person. So, better go for interesting incidents or ideas that raise questions which become the thread you will run through your essay and tie off in conclusion.
Ex. In "lending hands..." in my intro I started off with this... Gautam Buddha, a rich prince, came across endless misery on his contact with world outside his palace. He thought over it and decided to look for the truth that would set people free from misery, instead of emptying his treasury. Inherently, it is wiser to help people instead of merely handing out doles. Even in Mahabharata, Kunti does not ask for doles of easy life from gods, but asks for strength to endure a difficult life. Such are the Indian values that spread light of resilience and self reliance across centuries and across the world.
With this intro, I then transition into historical angle. So, you see there is a flow(clarification: mythology is not history :), but Buddha is a historical figure, a great one)
Now, in conclusion I use the philosophical angle and as Buddha is a great philosopher too, I get to complete my circle :) Here's how I conclude..
Handing out doles cuts at human dignity. It diminishes a person's esteem. Instead, by helping a person grows and character is built which helps the person persevere and even help others. This brings a virtuous cycle that pushes society forward on path of development, both individual and collective. Furthermore, it is said god helps those who help themselves. So, till the poor and weary man seeks and finds god, lets give help or should we say a helping hand.
5.Paragraph planning: 1000-1250 words in an essay...Say 50 words in a paragraph. For my handwriting, it took 10 words per line, so I had 5 lines in a para. 20-25 paras in an essay.
2-4 paras for intro, conclusion and transition from one block to another, so remaining 18-20 paras.
So, now depending on number of blocks in the mega framework, one can plan number of paras.
Also, this way essay will be balanced, wont be too many points on one aspect, starving the other.
So, in ex. "lending hands..." I had 5 blocks in my body leaving intro and conclusion. In each block I needed 4 points at least, which I came up with. Then within these you rearrange them by numbering to create a flow. Then you enrich by putting examples/events from current affairs like some scheme or statement of PM/VP/Pres/former Pres/CJI and others. This is a chance to highlight your awareness and to make your essay interesting. Only points makes essay bland and monotonous.
As you can see, with this para planning, essay does not seem like a big thing but a string of small topics connected together. That is how it must be, is what I feel.

6.Last but not the least. Practice.
Try this technique on many essay topics. Think of an interesting intro, transition, mega framework...block 1,2,3 and then points under them.. repeat.. Later try to think of current example on each point... That's it... this is the rough work you need to write an essay.

7.Next step is to write in full sentences. This is often under estimated but Ive seen that most of us think in some other language and write in English or think faster than writing speed. So, we tend to make lot of weird grammar mistakes. So, once in a month try to write down an essay or even a page, to see how you do in writing full sentences with appropriate wording. Ive seen so many of my friends getting stuck up on choosing the right word in middle of a sentence. It breaks flow of thought and also stops your pen, creates inertia. So, reading Yojana is important to build healthy vocab. Further, Ive seen that as soon as I try to go for flowery language, my meaning gets obscured and then Im busy looking for better words. Better to keep language simple and focus on proper passage of meaning to reader.

That's all folks!

I'll try to write some essays, not to instruct people, but just to share my ideas, at random. Please feel free to "critically analyze", "discuss", "comment" :)