1. Explain the working of a 4 Stroke IC engine?

A four-stroke engine (also known as four-cycle) is an internal combustion engine in which

the piston completes four separate strokes which comprise a single thermodynamic cycle. A stroke

refers to the full travel of the piston along the cylinder, in either direction. The four separate strokes

are termed:

SUCTION: this stroke of the piston begins at top dead centre. The piston descends from the top of the

cylinder to the bottom of the cylinder, increasing the volume of the cylinder. A mixture of fuel and air is

forced by atmospheric (or greater) pressure into the cylinder through the intake port.

COMPRESSION: with both intake and exhaust valves closed, the piston returns to the top of the

cylinder compressing the air or fuel-air mixture into the cylinder head.

POWER: this is the start of the second revolution of the cycle. While the piston is close to Top Dead

Centre (TDC), the airfuel mixture ignites due to the heat generated by compression in a diesel

engine. The resulting pressure from the combustion of the compressed fuel-air mixture forces the

piston back down toward Bottom Dead Centre (BDC).

EXHAUST: during the exhaust stroke, the piston once again returns to top dead centre while the

exhaust valve is open. This action expels the spent fuel-air mixture through the exhaust valve(s).

2. What is heat treatment and why is it done?

Heat treatment can be defined as a combination of processes or operations in which the heating and
cooling of a metal or alloy is done in order to obtain desirable characteristics without changing the
compositions. Some of the motives or purpose of heat treatment are as follows:
> In order to improve the hardness of metals.
> For the softening of the metal.
> In order to improve the machinability of the metal.
> To change the grain size.
> To provide better resistance to heat, corrosion, wear etc.

Heat treatment is generally performed in the following ways:

> Normalizing
> Annealing
> Spheroid sing
> Hardening
> Tempering
> Surface or case hardening

3. Explain the purpose of Lubrication in IC Engine?

> To reduce the friction between moving parts by maintaining a thin film

> To reduce wear & tear

> To reduce corrosion & carbon deposits

> To reduce & dissipate heat of the moving parts from inside to outside

> To reduce noise & vibration of the moving parts

4. What is the function of Thermostat in engine cooling system?

When the engine is too cold the thermostat close the main valve, thus stopping the flow to the
radiator. When the engine is hot, approx. 650C, it opens the main valve for normal circulation through
the radiator.

5. Why should a chain drive be used over a belt or rope driven drive?
State pro`s and con`s?

The advantages of using a chain drives are:

> In a chain drive no slip occurrence takes place.
> The chains take less space as compared to rope or belts as they are made of metal and offer much
strength.
> The chain drives can be used at both short and long ranges and they offer a high level of
transmission efficiency.
> Chain drives can transmit more load and power as compared to belts.
> A very high speed ratio can be maintained in one step of chain drives.
Some of the cons of using a chain drive are:
> The cost of producing chain drives is higher as compared to that of belts.
> The chain drives must be serviced and maintained at regular intervals and henceforth their cost of
ownership is high comparatively.

6. What is the difference between supercharger and turbocharger?

The key difference lies in its power supply, the supercharger will take its power from the crankshaft
whereas the turbocharger will draw power from exhaust gases that result from combustion. Both are
used to boost engine power & efficiency.

7. What are the different types of brakes and explain them briefly?

Disc Brakes: A friction system using a wheel brake to slow the rotation of the automobiles
wheels; brake pads are pushed against the brakes rotor with a set of callipers

Drum Brakes: A friction system using a set of shoes or pads to press against a brake drum

Single-Circuit Hydraulic Brakes: A master cylinder fed by a reservoir of hydraulic brake fluid
and connected by a system of metal pipes and rubber fittings attached to wheel cylinders;
each wheel has opposing pistons on band or drum brake; pressure is produced to push
pistons apart and force brake pads into wheel cylinder

Antilock Braking System (ABS): an electrical control unit, hydraulic actuator and individual
wheel speed sensors that work together to prevent brakes from locking up when they are
slammed on by rapidly pumping brakes when a potential lockup is detected; each wheel is
controlled individually to maintain traction

Power Brake Booster: a system utilizing the vacuum power naturally produced in an engine to
amplify a drivers foot pressure to stop even very heavy vehicles

Air Brakes: a system using air instead of hydraulic fluid to activate a standard disc or drum
brake, usually used in buses, trucks and trailers

8. What are types of Gears?

1. Straight Gear [spur gear] 2. Helical gear

3. Bevel gear
4. Worm gear
5. Rack and Pinion

Straight gear:-

These are also called as spur gears the gears having tooth in straight & parallel to the axis of the
shaft. These gears are used to transmit the power in gearbox of automobiles. This type of gears are
used to transmit more power.

Helical gear:-
In these helical gears the gears having the tooth with some angles with respect to the axis of shaft.
This angle doesnt meet more than 30-50. If the angle is increased the gear cant transmit the power
effectively and it effects the life of the gear.

Bevel gear:-

Bevel gears are used to transmit the power from one direction to another direction. For example the
power developed by one shaft is in X-axis & the power need to be transmit to 90 i.e., to Y-axis. Then
these gears are used. In these the gears having some slant & angled position.

Worm gear:-

In these the position of shaft are non-parallel to each other. In this type of gears a worm & a wheel
worm having a circular spiral gear like a spring in spiral binding. The wheel may have the tooth angles
or straight form. Then the power input is given to worm then the output may obtained at wheel
according to our requirement

Rack and Pinion :-

In this type of gear having a infinitely large diameter the tooth are laid flat.Torque can be converted to
linear force by meshing a rack with a pinion: the pinion turns; the rack moves in a straight line.

9. What is a bearing? What are the different types of bearings?

Bearing is a device that helps smoother movement with minimal friction which in turn helps enhances
efficiency and speed. Considering two types of loading, radial and thrust, there are different types of
bearings which help handle these loads. The basic difference in the types of loads is essentially due
to their ability to handle weight and different kinds of loads for various applications. Different types of
bearings are:

-Ball bearing
-Roller bearing
-Ball Thrust bearing
-Roller thrust bearing
-Tapered roller bearing
-Magnetic bearings

10. What is a process flow diagram? Explain a Thermal Plant.

A Process Flow Diagram is a user friendly, simplified sketch which illustrates general plant streams,
major equipment and key central loops and shows the relationship between major components in the
system. By using symbols to identify instruments and vessels it describes the primary flow course.
They also provide e detail of mass/energy balance data along with stream composition and physical
properties, however do not show minor components.

11. Who invented the four stroke engine? According to you which one is
more efficient, four stroke engine or a two stroke engine and why?

Nikolaus Otto invented the four stroke engine. Both, two stroke and four stroke have their own
advantages and disadvantages. 4 stroke is more fuel efficient. However, 2 stroke produces more
power.

12. Why do heavy vehicles use diesel engine?

The compression ratio of diesel engine is higher than the petrol engine, the reason for producing
higher torque. The efficiency of diesel engine increases with load. Diesel produces slow energy on
burning of fuel and the efficiency of the engine increases with load which is why diesel engine is
suitable and largely used for heavy vehicles.

13. What are difference between Welding & Brazing?

In welding concentrated heat (high temp) is applied at the joint of metal & fuse together. In brazing
involves significantly lower temperature & does not entail the melting of base metal. Instead, a filler
metal is melted & forced to flow into the joint through capillary action.

14. Explain the types of sensors.

(i) Temperature Sensor- This device collects information about the temperature from a source and
converts it to a form which is understandable by another device or person. Glass thermometer is the
best example where mercury acts as the temperature sensor.
(ii) IR Sensors- This device detects and/or emits infrared radiation to sense a particular phase in the
environment. Mostly thermal radiation is emitted by all the objects in the infrared spectrum. This type
of radiation is not visible to the human eye but the infrared sensor detects it.

(iii) UV Sensors- These sensors measure the intensity of the ultraviolet radiation. This form of
electromagnetic radiation has wavelengths which are longer than x-rays yet shorter than visible
radiation. UV sensors can discover the exposure of environment to ultraviolet radiation.

(iV) Touch Sensor- A touch sensor acts as a variable resistor based on the location where it is
sensed. Proximity Sensor- A proximity sensor detects the presence of objects that are placed in close
proximity without any point of contact.

15. How many types of suspensions are used in automobiles?

McPherson struts
Leaf spring
Coil spring
Torsion beam
Wishbone
Air Suspension

16. What is the role of Nitrogen in welding?

Nitrogen is used to prevent porosity in the welding member by preventing oxygen & air from entering
process. Other gases such as Argon, Helium, CO2 are also used.

17. What is meant by gear ratio?

A gear ratio is a direct measure of ratio of the rotational speeds of two or more interlocking gears or it
is ratio of number of revolution of the pinion gear to one revolution of the idler gear.

18. What is Flash Point?

The lowest temperature at which the vapour of a combustible liquid can be ignited in air.

19. Why are Head Gaskets blown?

Normally head gaskets blow, when the engine overheats & can blow from incorrect installation or poor
design. Head gasket expand & contract according to the engine temp. Over a long period of time the
cycles repeat & gasket fails.

20. Explain the significance of Governor in automobile

 It is used to regulate the speed of the engine during variation in loads. Variation in load demands
correct flow of fuel supply. This is done by governor.

21. What is difference between Safety Valve & a Relief Valve?

A safety valve is a control mechanism that releases pressure when it crosses a set limit or threshold &
then reset back to its original position. A relief valve is a mechanism to instantly relieve the pressure,
that is triggered in extreme circumstances when pressure has suddenly exceeded or approaching
failure criteria.

22. What are the methods of extinguishing fire?

1) Starvation. Separating or removing the burning material from the neighbourhood of the fire.
2) Blanketing. Preventing the air flow to the fire.
3) Cooling. Lowering the heat created by burning materials

23. What are the measures of IC Engine performance?

Engine types vary greatly in a number of different ways and following are its measures of
performance:
1. energy efficiency
2. fuel consumption
3. power-to-weight ratio

24. What are the types of pumps?

- Positive Displacement
- Rotary lobe pump, progressive cavity pump, rotary gear pump, piston pump, diaphragm
pump, screw pump, gear pump, Hydraulic pump, vane pump
- Centrifugal Pumps
- end suction pumps, in-line pumps, double suction pumps, vertical multistage pumps, horizontal
multistage pumps, submersible pumps, self-priming pumps, axial-flow pumps, regenerative pumps

25. State Pump affinity laws

The Pump Affinity laws predict the effects of changing the speed of a centrifugal or rotary pump on
flow rate, head and power. Being able to predict these affects allows the rotating equipment engineer
to examine the effects before implementing the changes.

The laws can be summarised as follows

Flow rate is directly proportional to pump impeller speed, e.g.

F1 / F2 = rpm1 / rpm2 where F = flow rate, and rpm = impeller speed
The ratio of Heads is directly proportional to the square of the ratio of pump impeller speeds, e.g.
H1 / H2 = (rpm1 / rpm2)2 where H = Head, and rpm = impeller speed

The ratio of Pump powers is directly proportional to the cube of the ratio of pump impeller speeds, e.g.
P1 / P2 = (rpm1 / rpm2)3

26. What is Pascal law? Applications?

- Pascal's law or the Principle of transmission of fluid-pressure states that "pressure exerted anywhere
in a confined incompressible fluid is transmitted equally in all directions throughout the fluid such that
the pressure ratio (initial difference) remains the same.

Application- Hydraulic jacks, Car lifts, Fork Lifts

27. Explain in drawing a single acting cylinder with control valve