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Opinions shared here are personal and not related to my professional position or capacity. Aim is to work on improving lives of people, with truth and service.

Wednesday, 24 August 2016

Power plants Turbomachinery

This area drains much energy and gives poor returns. Main problem is that the textbooks are very poorly written. Much of it discuss power plants in shallow manner or go too deep into practical aspects. The middle ground of numericals, problem solving is left wide open. Books like Eastop  McConkey are ones that save students in the end.

Power plant economics is quite straightforward. So it is also good for scoring. Same goes for emissions control part related to power plants.
PP economics and emissions

Power plant cycles are simple only with modifications of Rankine cycle. Cascades, combined cycles etc are very tedious. Also, often the question itself has a piece of info missing, which makes taking up these questions a big risk. On other hand, much of these questions are taken straight from textbooks, so if one has enough experience, one can handle it better(and go for 300+ total in mech)
Unfortunately, I did not have much interest in this area, so my effort is upto bare minimum.
powerplant cycles

Rankine and gas turbine cycles are better topics to invest time and effort, from  exam point of view.

Turbomachinery is another topic which I largely left, as it just drains time and effort and brings frustration. There are no universal symbols being used, no standards followed in making diagrams(velocity triangles). The subject is a big mess and unfortunately, requires lot of decoding symbols and terminologies. Sad part is technically, it is simple, but the researchers have complicated it to such an extent that it is comparable to financial securities being taught to a layman.
I can not recommend any good book for the topic, as frankly there is none. Most of the books use different symbols and sign conventions. I have tried to solve some questions and collected them topicwise.
Axial compressors, centrifugal compressors and gas turbines are subtopics one can look at.
Better to read it from a single book. Books on turbomachinery and those on fluid machinery have different symbols, so better to stick to one.
compressors and gas turbines
Steam turbines(impulse and reaction) also should be studied specific to demand of exam. No extra points for becoming non-certified PhD
compressors and steam turbines

Steam generation, boilers, draught is simple to understand and reproduce. These notes should be enough to cover the demand of the exam.

IC Engines 2

IC engines is topic that gives good returns on time and effort. Mathur Sharma is a good book that covers much of the syllabus relevant to cse. There are many who prefer Ganesan but I found former better. If one does like to dig deeper, one can go for Heywood.

IC Engines 1 was a post I made in the beginning and wanted to make it extensive in terms of coverage but I could only put up the skeleton and filling it up would be like writing a book(too much work and time required)

So, here are the questions, mostly solved, on different topics.

ESE qna 1
ESE qna 2

CSE questions topicwise
Performance calculations and balance sheets
Combustion, knocking, fuels, emissions
Carburetion and diesel injection


RAC 2

RAC 1 is a messy post as it was made in the beginning, while I was figuring out how to upload so many pages. Then I made other posts where I linked questions with pages uploaded on google drive(too much work). Now, I am hastily uploading my notes in chunks, as I am getting tired of the scanning, uploading, linking etc. So, I leave it to the recipient to further organize the material.

Refrigeration is an awesome topic as it is quite neatly laid out in books. Questions are quite straightforward and methods are simple.
Sub topics are VC cycle, components like compressors and expansion valves, refrigerants, LVHE, VA cycle, gas cycle

refrigeration QnA

Psychrometry is also a scoring area. There are some basic derivations and diagrams which are directly asked. Numericals too are easy to deal with.

psychrometry qna

Airconditioning is the tricky part. There are so many technicalities, that sometimes it is even difficult to figure out where to start. Another problem is that often, some piece of data is not given in the question. Then one has to assume some value and continue but it is risky and also creates lot of doubt in one's mind. So, better to identify if the question is familiar, otherwise no point in taking much risk.

AC qna


Tuesday, 23 August 2016

Gas and Fluid Dynamics GD FD

It is a fringe topic in syllabus. It appears at end of textbooks of thermodynamics and is often poorly explained/covered. Book by Prof SM Yaha on Compressible flow is the best book for the topic. Unfortunately, the symbols he has used in the book are different from those used usually by everyone, which makes it painful to go thru the topic. So, I have decoded and made notes using usual symbols and covering those topics/derivations that are relevant to the exam.
GD notes

GD has only a handful of subtopics: derivations for convergent divergent nozzles, Rayleigh flow, Fanno flow, Normal shocks
But the difficult part is remembering the derivations and formulae for these topics
sub-topicwise solved GD questions

Fluid statics/dynamics is another topic which is ill treated by the exam. The subject as such is extensive which is clear if one sees the size of any textbook for the same(RK Bansal, Frank M White). So, it takes lot of time and returns are poor. So, I made notes in QnA form taking stuff from ESE questions.
Fluids notes ESE QnA

Some solved question from CSE on fluids

Monday, 11 July 2016

2017 ESE CSE

There are many among us sharpening their blades for the 2017 season. I am specifically interested in the preparation of those taking up Mechanical Engineering as optional in CSE and are also naturally appearing for ESE(good practice for optional + good backup if you need one).
But, the game has changed quite a bit, with new schedule and structure, syllabus etc.

So, there is ESE prelims on 8 Jan 2017. There will be two papers instead of earlier three.
They have clubbed two engineering papers into a single heavy weight paper of 300 marks(3 hours). GS earlier had bit of quant, apti and english. Now there is also ethics and engineering aptitude. From model questions, it appears to quite vague, so I'd say not a game decider. I suppose everyone would be as confused. But I suppose reading up bit of ethics would help, say like Lexicon(beginner's book for GS4 in CSE). Engg aptitude seems to be much of graduation first year course material(NDT, materials, etc), so one can start by brushing up on that.

GS seems to be diluted in weightage. So, good for engineers, as they get better shot and people like me who bash up GS paper with CSE expertise don't get an edge. On other hand, the stakes are now really high on Engineering objective paper. Furthermore, people who are preparing for ESE and CSE both will now have to study more work to do, as they will have to put in efforts for GS which wont help much in ESE.

Next stop, ESE mains 14 May 2017, same as before 300+300

In a month, there is CSE prelims on 18 June 2017. So, not much breathing space to revise well on GS for CSE. On other hand, at least you will have your optional freshly done and exam ready.

As stage1 is completed in Jan itself, I suppose results of ESE mains will be out a bit earlier, so instead of November, I expect they should be out a bit earlier(say Sept/Oct, pure speculation). So, it becomes bit of a pain for CSE mains preparation. As, interview preparation is the most useless kind of preparation. We tend to cover shallow tidbits of much of the syllabus, so even the subject does not get revised well for CSE mains optional.

In that you have CSE mains, from 28 October 2017. I remember for 2015, I had my interview on 3rd Dec and mains from 18 Dec. I was at ease with GS material for interview thanks to CSE prep, but my engg(interview specific) was weak. But then, if one has reached interview and has a little bit of wide reading in engg subject, the technical part of interview goes well.

So, that is my commentary on the timeline, now if we are to attempt actual planning, then it would be something like this...(assuming I am aspiring for ESE+CSE)

5 months in hand(aug-dec). My priority would be to clear ESE prelims and be ready for CSE prelims, as I wont get much time later.
Now, it is very tricky to lay down an actual plan as it would crumble within a week. There are just too many factors and there is bound to be turbulence as one covers ground. We have to cover GS prelims from CSE perspective, which would naturally help in ESE prelims. In parallel, we have to cover objective part of Engg, which has to be done really well, as in or out comes down to this now.

So, as always, I would start with previous year questions and basic books, then go for some more reference books.
5 months = 20 weeks. Lets just say we have only 18 weeks. 6 subjects in GS for prelims, 12 subjects in mech engg. So, we can have a weekly cycle. Take up 1 GS subject and 2 engg subjects(1 from each paper). Doing this, we comfortably cover whole syllabus in 6 weeks. Not bad!!
Of course will suffer, coz lets face it, it is not enough. But its alright, it is just first cycle!
We have 2 more of such cycles left. THIS is a critical part, where I have seen many candidates going astray. One has to take these deadlines seriously. What happens is we take the 1st cycle too casually and end up covering less than 50% of what we planned. In further cycles, we end re-reading same stuff and suddenly 2 weeks before exam, the crushing realization comes... Bhai nahi ho paega!
So, I advise extreme ambition in 1st cycle. One can use rock music, energy bars, beverages to keep yourself going and cover at least 3/4th of syllabus.
I leave the fine details of sequence of subjects in these weeks and intra-week planning open ended.
If you are going for a test series, see how you can pick up topic so that you can sync your schedule with the test schedule.

Now, assuming one goes through with this 18 week course and revision and mock tests in last 2 weeks and gives prelims. So, for ESE mains one again has 5 months(jan-may).
So, another 18 week plan has to be made. Now, this is a great relief, that one only has to study subjective part and not cram up garbage for objective papers(as required earlier). This is a great luxury and must be used to cover GS for CSE mains in parallel.
It is not possible to cover(to satisfactory level) 2 engg subjects in 1 week, so can't go for 6 week cycle. One will have to go for 12 week cycle in beginning. 1 topic 1 week, complete focus.
Now, in parallel one can take up GS mains.. 4 papers.. one can leave GS4 aside for later.
So, 3 weeks each for GS1,2,3.
In remaining 6 weeks, one can leave GS mains aside, and take up only engg. Since, it is second cycle, one can take 2 subjects in a week.
We have 2 weeks in end for revision. ESE mains goes well, and we are back to brushing up GS prelims. 4 weeks, full on prelims prep. Should be enough considering the serious study done in Aug-Dec period.
After CSE prelims, there is nothing much to worry about. Engg is ready for mains. One can shift more time towards GS mains.

There is lot of juggling going on in this preparation. But, we get the comfort of 2 opportunities every year compared to many who wait the whole year only for CSE. So, to all engineers, I say.. Lets be professional and show all of them how its done!! All the best!

PS. I wont be proof reading the above material, as I tend to select everything and delete after doing so. Kindly bear with the typos and grammatical errors..
 

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
-----------------------------------------------------------------------------------------------------------
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.
----------------------------------------------------------------------------------------------------------
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
-------------------------------------------------------------------------------------------------------------------
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.
---------------------------------------------------------------------------------------------------------------------
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