TNPSC (TECHNICAL EXAM)

MECHANICAL, PRODUCTION AND MANUFACTURING

ENGINEERING

Unit I: Mechanics, Kinetics and Dynamics (18 Questions)

Statics of Particles, Equilibrium of Rigid bodies, Mechanism of Deformable Bodies,
Properties of Surfaces and Solids, Centroid, Centre of Gravity, Dynamics of Particles,
Elements of Rigid Body Dynamics, Basics of Mechanisms, Kinematics of mechanisms,
gyroscope, Gears and Gear Trains, Fly Wheels and Governors, Balancing of Rotating and
Reciprocating Masses, Friction in Machine Elements, Force Analysis, Balancing, Single
Degree Free Vibration, Forced Vibration, mechanisms for Vibration Control, Effect of
Damping, Vibration Isolation, Resonance, Critical Speed of Shaft.

Unit II: Strength of Materials and Design (20 Questions)

Stress, Strain and Deformation of Solids, Combined Stresses, Theories of Failures,
Transverse Loading on Beams, Stresses in Beams, Torsion, Deflection of Beams, Energy
Principles, Thin Cylinders and Thick Cylinders, Spherical Shells, Fundamentals of Design for
Strength and Stiffness of Machine Members, Design of Shafts and Couplings, Design for
Static and Dynamic Loading, Design of Fasteners and Welded Joints, Reverted Joints, Design
of Springs, Design of Bearings, Design of Flywheels, Design of Transmission Systems for
Flexible Elements, Spur Gears and Parallel Axis Helical Gears, Bevel Gears, Worm Gears
and Crossed Helical Gears, Design of single and two stage speed reducers, Design of cam,
Clutches and Brakes, Design of Piston and Connecting Rods.

Unit IV: Strength of Materials (25 Questions) [DIPLOMA]

Properties of engineering materials– Mechanical testing – Simple stresses and strain – Elastic
constants – Properties of sections (centroid, moment of inertia) – Thin cylinders – Theory of
simple bending – Torsion and springs – Shear force and bending moment – Friction.

Unit IX: Design of Machine Elements (15 Questions) [DIPLOMA]

Engineering materials – Types - Design of Joints and Fasteners – Design of shafts, keys and
couplings – Design of bearings – Belt drives and gear drives.

Unit III: Fluid Mechanics and Turbo Machinery (20 Questions)

Fluid properties, fluid statics, manometry, buoyancy, control volume analysis of mass,
momentum and energy, fluid acceleration, differential equations of continuity and
momentum, Bernoulli’s equation, Dimensional Analysis, viscous flow of incompressible
fluids, boundary layer, elementary turbulent flow, flow through pipes, head losses in pipes,
bends. Turbomachinery: Pelton wheel, Francis and Kaplan turbines - impulse and reaction
principles – velocity diagrams, pumps and its applications-Valves and Types - Theory of Jet
Propulsion- Pulse Jet – Ram Jet Engines, Online Continuous Flow Monitoring System.

Unit VII: Fluid Mechanics and Machinery (15 Questions) [DIPLOMA]

Fluid properties – Pressure measurements – Fluid flow – Flow through pipes – Reciprocating
pumps – Centrifugal pumps – Hydraulic turbines – Components of hydraulic systems and
pneumatic systems.

Unit IV: Thermal Engineering and Thermodynamics (30 Questions)

Basic concepts, Zeroth, First and Second laws of thermodynamics, thermodynamic system
and processes, Carnot cycle. irreversibility and availability, behaviour of ideal and real gases,
thermodynamic relations, properties of pure substances, calculation of work and heat in ideal
processes, analysis of thermodynamic cycles related to energy conversion, Fuel and
combustion, Fuels Characteristics, Emissions and Controls, Testing of IC Engine-Renewable
sources of Energy.
Power Engineering: Steam Tables, Rankine, Brayton cycles with regeneration and reheat. I.C.
Engines: air-standard Otto, Diesel cycles. Refrigeration and air-conditioning: Vapour
refrigeration cycle, heat pumps, gas refrigeration, Reverse Brayton cycle; moist air:
psychometric chart, basic psychometric processes.

Unit V: Thermodynamics (15 Questions) [DIPLOMA]

Systems – Basics – Thermodynamic laws – Properties – Processes – SFEE – Air compressors
– Types – Intercooling – Turbines – Boilers – Steam properties – working principle of steam
power plant - Main elements of a nuclear power plant – Modes of heat transfer –
Psychrometric properties, Processes.
Unit VI: Heat Power Engineering (15 Questions) [DIPLOMA]
Working principle and comparison of otto and diesel cycles - construction and working of
two stroke and four stroke engines - Heat balance test on I.C. engine – Fuel supply systems of
petrol and diesel engines – Ignition systems – Cooling systems – Lubrication systems –
Refrigeration – Types – Factors affecting human comfort – Air conditioners – Types.
Unit V: Heat and mass Transfer (25 Questions)
Modes of heat transfer - one dimensional heat conduction, resistance concept, electrical
analogy, unsteady heat conduction, fins dimensionless parameters in free and forced
convective heat transfer, various correlations for heat transfer in flow over flat plates and
through pipes, thermal boundary layer, effect of turbulence, radiative heat transfer, black and
grey surfaces, shape factors, network analysis; heat exchanger performance, LMTD and NTU
methods.
Basic Concepts of Mass transfer, Diffusion Mass Transfer, Fick’s Law of Diffusion Steady
state Molecular diffusion, Convective Mass Transfer, Momentum, Heat and Mass Transfer
Analogy, Convective Mass Transfer Correlations, Radiactive Heat Transfer.
Unit VI: Materials Science and Metallurgy (25 Questions)
Constitution of alloys and phase diagrams, Iron – Iron Carbide Phase Diagram - steels, cast
iron, phase transformations - diffusion - TTT diagram, ferrous and nonferrous alloys, heat
treatment of ferrous and non-ferrous metal, surface modification techniques, powder
metallurgy, non-metallic materials, mechanical properties and testing, crystal defects and
strengthening mechanisms, conducting and semi conducting materials, magnetic and
dielectric materials, Engineering ceramics, Engineering and commodity polymers,
composites, nano-materials.
Unit VII: Production Technology (22 Questions)
Foundry Technology - types of pattern, cores, moulding and casting methods, Solidification,
design of castings, defects, Melting Furnaces, Hot and Cold working, Metal Forming
Processes - types, Defects and Remedies, Sheet Metal Operation, metal joining processes,
types and design of weldment, welding metallurgy, welding defects, Casting, Welding
Inspection (NDT), Manufacturing of Thermo Setting and Thermo Plastic Products, Metal
cutting, Cutting Tool Nomenclature, Machinability machine tools - center lathe, drilling,
milling, grinding, gear cutting and broaching, Machining Time Calculation, unconventional
machining processes, Micro Manufacturing, CNC machine tools, Manual Part Programming -
Machining and Turning Centre.

Unit II: Production Technology (25 Questions) [DIPLOMA]

Foundry - patterns - special casting techniques - welding - hot and cold working – drawing,
rolling and forging - powder metallurgy – Processing of plastics - lathe work - planner -
shaper - slotter - drilling machine - milling machines - grinding machines - broaching -
boring and jig boring - Gears manufacturing practice - Heat treatment and metal finishing -
press work – Non conventional production processes – Semi automats – Automats.

Unit VIII: Metrology and Quality Control (15 Questions)

Limits, Fits and Tolerance, Linear and angular measurements, Interferometry, laser
interferometers - Types, Computer Aided Inspection, Basic concept of CMM - Types of
CMM, Machine vision, Form measurement-Straightness- Flatness, Roundness, Surface finish
measurement, contact and non-contact method, Measurement of power, flow and
temperature. Statistical quality control, control charts, acceptance sampling, reliability, TQM,
5S, ISO standards.

Unit X: Metrology and Measurements (25 Questions) [DIPLOMA]

Scope of metrology – Accuracy – Precision – Limits – Fits – Tolerance – Linear and angular
measurements – Measuring instruments – Form measurements – Surface textures and lays –
Comparators – Gauges – Measurement of mechanical parameters – Computer aided
inspection – Measurement of force, power and flow

Unit IX: CAD / CAM / CIM / FEA (13 Questions)

Fundamentals of Computer Graphics, Geometric Modeling, Visual Realism, Assembly of
Parts, CAD Standards, Fundamentals of CIM, Production Planning and Control, Computer
Aided Process Planning, Cellular Manufacturing, Flexible Manufacturing System and
Automated Guided Vehicle System, Group Technology, Production Flow Analysis, Industrial
Robotics, Additive Manufacturing, Just in Time(JIT), lean manufacturing, One Dimensional
Problems in FEA, Two Dimensional Scalar Variable Problems, Two dimensional vector
variable problems, Isometric Parametric Formulation.

Unit VIII: Computer Integrated Manufacturing (25 Questions) [DIPLOMA]

Computers – Construction – Types – MS Office – CAD – geometric modeling – wireframe,
surface and solid modeling – graphic standards – CAM – group technology – part families –
parts classification and coding – CAPP – types. CNC – components of CNC – ATC – CNC
EDM. Part program – format – coordinate system – types of motion control – types of
interpolation – G and M codes – sub program – canned cycles – FMS – AGV – Robotics –
Rapid prototyping.

Unit X: Industrial Engineering and Management (12 Questions)

Work study - Techniques, Method study and work measurements - objectives - basic
procedure, machine loading and scheduling, product sequencing, inventory control - E O Q -
quantity discounts, ABC Analysis material handling systems, operations research, Linear
Programming, simplex method, Transportation model, Assignment model CPM and PERT,
Queuing Models. Management theory and practice, planning - Decision making, Organising,
staffing, Motivation, Leadership, controlling, control techniques, Industrial Safety - Standards
– OSHA.

Unit I: Industrial Engineering and Management (25 Questions) [DIPLOMA]

Selection of site – Plant layout – Plant maintenance – Plant safety – Work study – Method
study – Work measurements – Functions of Production planning and control – Principles of
Management – Personnel management – Fixing selling price of a product – Break even
analysis – Make or buy decision – Depreciation methods – EOQ – Supply chain management
– TQM tools – Control charts– ISO 9000 Series quality standards – QS 14000.

Unit III: Electrical and Electronics Engineering (15 Questions)

Units, Ohm’s law, Kirchoff’s law, Faraday’s law - D.C. Circuits, batteries - electro
magnetism - single phase and three phase A.C. circuits - Induction motors – Servo motors
Stepper motors – Diodes – resistors – capacitors – transistors – logic gates - PLC – Sensors.