UPPSC Combined Junior Engineer Syllabus

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PAPER I : Section A

1. Applied Mechanics

Forces : Transferability, moments and couples, funicular polygon, Lam’s theorem, Varigon theorem, Friction: limiting and dynamical friction, coefficient of friction: bodies on inclined planes, simple screw jack.

Machines : basic terms-mechanical advantage, velocity ration, mechanical efficiency. Lifting machines system of pulley’s Weston differential pulleys.

Stress & Strains : volumetric and lateral strains Hook’s law, Poisson ratio, modules of rigidity, bulk modules. Application to bars and composite sections.

Beams & Trusses : determination cases, Bow’s nation. Types of supports. analytical methods of joints and sections. hoop stress, longitudinal stress. charges in dimensions and volumes of thin shells subjected to internal pressure.

2. Theory of Machines and Automobile Technology :

Slider crank mechanism: turning moment in single cylinder engine: Fluctuation of speed and energy: crank effort diagrams, flywheel size Gear drive: gear trains, simple, compound epicycle and reverted. Automobile gear box. Automobile differential.

Clutches : Function of clutch in automobiles: single plate and multiplate clutches friction torque for uniform wear and uniform pressure.

Cams : Concept, classification of different cams and followers. Application to automobile Engine, simple Cam Profiles for uniform velocity, SHM and uniform Acceleration.

Balancing : Static and Dynamic balancing of masses rotating in same planes, Basic concept of sevral masses rotating in different Planes, Application of automobile engines.

Belt Drive : Derivation of limiting rations of Driving tensions, centrifugal tensions. V-belts ropes and chains.

Dynamo-meters : Classification Functions, Construction and Working Concepts.

Governor : Functions, classification, Watt, Porter Hartnell, Hartung, Elementry Numerical About Height, maximum and minimum Controlling Forces etc.

3. Mechanics of Solids :

Mechanical Properties of Materials :- concept of stress and strain, stress-strain curves of mid steel, aluminum, cast iron, rubber etc. various modulli, determination of stresses and strains in bolts, slepped bars, compound bars and columns. Obligue plane. Principal stresses, Mohr circle shear force/Bending moments/ deflection: analysis of cases of concentrated and uniformly load.

Shear force and bending moment diagrams: cantilever, simply supported, overhanging beams.

Strain Energy : resilience, derivation of formulae of strain energy for uniform bars in tension, shock load, shear stress. Modulus of resilience. Torsion: solid and hollow circle shafts-polar modulus, weights, power transmitted.

Springs : close coiled helical springs, Laminated springs. Maximum stress and central deflection, (Simple numerical, no proof of formulae).

Columns & Struts : long and short columns, slenderness ratio. End conditions and equivalent lengths. Euler and Rankine formulae (no derivation).

PART B

Material Science :

Materials: Ferrous-iron, steel alloy steels. Nonferrous matels-aluminium, zinc copper, tin, lead Nonmetallic materials-timber, polymers. Basic knowledge of their production.

Structure of materials: Crystalline, amorphous, arrangement of atoms, Crystal structural, imperfection. Mechanical properties of common metals and alloys, deformation.

Heat treatment: Iron- carbon equilibrium, TTT curves: recovery, recrystallisation and grain growth. Elementary concepts of hardening, tempering annealing normalizing and case hardening.

Alloy elements: effects of alloying Cr, Co, Sl, Mn etc. Tool steels stainless steels, heat resitsing alloys, spring steel, Nonferrous materials: duralumin, solders brass, bronze, gunmetal, inconel, Non-metalic materials: timber-ply wood, hard board, seasoning.

Polymers: thermoplasts and thermosets, Heat insulating materials. Glass wool thermocol, rubber, Electric insulating materials: bakelite, mica refractory materials: composites.

Design and Estimating :-

General design considerations for machine parts: Steps in machine design, factor of safety. Mechanical properties of materials, selection of materials. Machine parts subjected to the following loadings: (I) Direct and shear loads: threaded connections, cotter and knucle joints. (II) Bending moment: design for railway wagon axle and road vehicle axles. Proof load and proof stress.

Semi elliptic laminated springs: maximum stress and deflection. (III) Twisting moment: solid and hollow shafts. Design of keys and coupling bolts in rigid flanged coupling.

Reveted and welded joints: types of reveted joints, strength, efficiency, safe load and pitch of revets, lap and butt joints. Common types of welded joints: Theories of failure: maximum principal stress theory, maximum shear stress theory, concept of equivalent bending moment and torque.

Rolling elements bearing: equivalent load dynamic capacity, life of bearings. Estimation of material requirements: estimation of weight of simple machine parts. Review of the area/volume of triangle, hexagon octagon, cylinder, frustum of cone and pyramid etc.

Estimation of time for common operations: turning, facing threading, drilling, shaping, chamfering, Simple problems pertaining to above.

Estimate of cost: concept of costing-direct materials, indirect materials, direct labour, indirect labour, overhead expenses. Break-even analysis. Cost estimation of welding: cost of materials, fabrication, welding. Finishing and overhead expenses.

Industrial Engineering :-

Plant Layout: general plant locations, selection of plant site. Product layout process layout.

Standardization: nation and international standards, value of standardization. Standardization techniques and problems.

Quality control: elements of quality control and objectives. Frequency distribution. X-R charts. P-charts and acceptance sampling concept of production. Inspection and its objectives. Types of inspections.

Work study: flow process chart, flow diagrams, work measurement, time study. Time and motion study. Products, planing and control: sales forecasting and its uses: Planning-products, process. parts, material Optimum batch quantity for production and inventory. Routing dispatching and follow-up activities.

Inventory control: elements of control procedures. types of controls inventory controls. Inventory control system of bin and records cycle system. Safety stock concepts.

Material Handing: factors in material handing problems. Reduction of cost and time through improved material handling. Material handling equipment: lifting, lowering, transporting and combination devices.

Industrial safety: need for safety-legal humanitarian, economic and social considerations, Safety at, work place-unsale conditions ad hazards-electrical hazards, lighting, ventilation heat control, noise and vibration, fire and explosion, chemical hazards; hygiene. Brief knowledge of relevant acts like factory act, Workman compensation act, Indian Boiler act, Indian-electricity act, explosive act.

PAPER – II

PART – A

Thermal Engineering :-

Boilers: fire tube, water tube, mountings and accessories. Equivalent evaporation: efficiencies: Steam and Gas turbines: impulse and reaction. Turbine components. Classification.

Steam condensers: components and construction features. Internal combustion engines: classification. Two stroke and four stroke engines. Main components and their functions. Air standard cycles: Otto, Diesel, dual, efficiencies. Engine lubrication, cooling systems.

Air compressors: Types reciprocating and rotary: single stage and two stage compressors. Simple numerical problems.

Refrigeration and Air Conditioning :-

Refrigeration: various cycles. COP Representation of cycles in p-V-Ts and P-H diagrams. Vapour compression system: wet and dry compression. Domestic refrigerator, Vapour absorption system: cycles of operation. Simple numeric problems.

Refrigerants: classification, properties- SO2, CO2, NH2, Freon-12 etc. Air conditioning: psychometry: Basic ideas of salient terms-dry and wet bulb temperature dew point, enthalpy, sensible heating, humidification and dehumidification, sensible heat factor, Basic knowledge of room air conditioning, Central air conditions systems.

Hydraulics & Hydraulic Machines :-

Fluid properties: pressure-depth relationship. Total pressure on lamina: condition of equilibrium of floating bodies, meta center and meta centric height (simple numerical problems).

Fluid dynamics: types of flow, equation of continuity, Bernoulli equation, orifices, coefficients of contraction, velocity and discharge, Minor losses in fluid flow, Venturimeter, orifice meter, Pilot tube.

Notches and weirs: rectangular notch, V-notch: Francis and Bazin formulae for rectangular weirs. Broad crested weirs. Flow through pipes: friction loss Darcy Weisbach equation. Simple numerials.

Channels: uniform flow in rectangular and trapezoidal channels: Chezy and Manning equations. Most economical selections. Hydraulic Machines: Impulse and reaction turbines: Pelton: Francis, and Kaplan turbines-constructional and operational features. Velocity diagrams.

Pumps: centrifugal and reciprocating pumps. Basic knowledge of constructional and operational features.

PART – B

Manufacturing Processes :-

Metal forming processes: classification on the basic of properties of deformability fusibility such as rolling, forging, drawing, extruding, pressing, punching, blanking, spinning.

Welding: concept of various welding processes-electric arc, residance thermit, metal-inert-gas, laser beam, election beam, electron beam, explosion and ultrasonic, Welding of different materials in Industries: plastics, alumininum, copper, brass, bronze, alloy steels, cast iron stainless steel: oxyacetylene method, welding arcs: initiation, structure, types metal transfer characteristics. Different types of electrodes. Basic knowledge of testing of welds are relevant welding code. Foundry practice: patterns and moulding-pattern types, materials allowance, layout, colour scheme, defect. Cores.

Moulding prosses: mould materials, types of sands, parting powders, sand mixing and preparation. Moulding defects. Melting and pouring Basic knowledge of refractory materials and fluxes. Furnaces-cupola. pit, tilling and electric types. Special castling: shell mould casting, die casting, investment mould casting, Centrifugal and continuous casting, full mould casting.

Powder metallurgy: basic knowledge of the process: production of metal powders, blending, compaction sintering etc. self lubricated bearing Advantages and limitations of the process.

Machine Tool Technology & Maintenance :-

Machine tools: Basic common features, drive systems, sources of power, work tool holding devices, speed varying systems, mechanical methods of providing automatically in machine tools.

Lathe: various parts, their functions and kinematics: lathe accessories and attachments. Capstan and turret lathes. Common lathe tools. Operations carried out on lathes such as turning, taper turning, drilling, screw cutting, reaming, knurling. common lathe tools and their uses, simple knowledge of computer numerical control (CNC) lathes and automation.

Milling machines: types components general maintenance. Operations such as plane milling, angular milling straddle milling, spur gear milling, Indexing, Shaping, plaining and slotting machines: components, working principle, quick return mechanism, types of tools used, their geometry.

Drilling and Boring machines: constructional details and principle of working. Classification such as simple and Radial types. Tools used, Maintenance: general and periodic.

Grinding Machines: types common abrasive materials grains gifts, speeds and feeds. Use of coolants. Jigs and Fixtures: difference between jigs and fixtures, types of jigs cooling processes: coolants and cutting fluids-their functions: selection for difference material and operations.

Workshop practice & production Technology :-

Workshop technology: scope in engineering, Brief survey of different shops general contained in a standard engineering workshop viz. carpentry, foundry smithy, sheet metal, fitting painting and machine shops carpentry: common carpentry tools-their classification such as marking and measuring holding and supporting, cutting and sawing, drilling and boring, striking and turning (name of parts functions and specifications only).

Joining of timber components:- types of joint common defects likely to occur in joints: their causes Foundry: basic knowledge of tools used in foundries. Pattern-types, uses and allowance: green sand moulding: sand preparation, and additives, parting powders, problems in moulding uses of cores rises gates chills etc.

Smithy: basic concepts of operations in smithy shop such as fullering, upsetting, swaging, forge welding, drawing down, Tools used in smithy (names, functions and size specifications only) smithy forge, blower, shovel, anvil swage block, striking tools punch, draft and hammers.

Sheet Metal shop: basic knowledge of operations such as laying out, shearing, blanking, seaming, burning stamping etc. tools in sheet metal shop used for marking, measuring, punching fitting shop: fastener like rivets, bolts, nuts screws, keys, pins etc. (basic understanding only). Tools used in fitting shop such as threading tools, dies taps, vices, wrench and spanners, hack saw, drills, (names function and specifications only.

Painting shop: surface preparation, sand and emery papers, varnishing and polishing common materials used such as red oxide, putty yellow clay, defects likely to occur in painting and their remedies.

Machine shop: elementary theory of metal cutting chips-geometry of formation. Brief idea of newer machining processes such as abrasive jet machining, ultrasonic machining, Chemical machining, electric discharge machining, laser beam machining, electron beam machining plasma arc machining. Metal finishing processes such as diamond machining, honing lapping buffing etc.