General Principles of Design, Drawing & Safety

New Pattern for UPSC ESE Exam

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First Edition : 2016

Second Edition (Revised) : 2017

Typeset at : IES Master Publication, New Delhi-110016

PREFACE

Giving life to an engineer’s dream for the betterment of society involves Design, Drawing and Safety. With the increasing complexities of economy, as well as the ensuing disruption in IT, besides the stringent safety rules, this inter-disciplinary subject has become challenging to comprehend from exam point of view.

Looking at the nature of Engineering Services Examination (ESE), and the level of questions being asked, the conventional approach of preparing through theory and examples does not serve the purpose. This book attempts to provide logical reasoning through mathematical analysis, gives a clear insight into the concepts, and paints a complete picture in front of your eyes. For students to discover the extent of their learning, practice questions have been provided at the end of this book.

In their endeavour to give students the best, Mr. Bipin Thakur has shared his subject knowledge of Design and Safety, and Mr. Himadri Shekhar (Aahil) that of Drawing in this book in an easy to understand language that gives in a complete clarity of thought. As a result, what students get is their collective wisdom that breaks free the constraints of engineering students in appreciating the General Principles of Design, Drawing and Safety.

As you navigate through this book, a slew of diagrams, flow charts, mind maps and tables, pack a tango that your eyes can relish on. This book is an ESE aspirant’s delight that communicates, connects, and builds upon the exam preparedness right up to the standards of the UPSC.

IES Master Publication New Delhi, 2017 CONTENTS

Section Description Page No.

Preface (iii)

Engineering Drawing 01-134

Chapter 1 INTRODUCTION TO ENGINEERING DRAWING 1 – 08

1.1 Introduction …(1)

1.2 Drawing Sheets : [IS 10711 : 2001] …(1)

1.3 Drawing Board : [IS 1444 : 1989] …(2)

1.4 Scales …(3)

1.5 Mini Drafter …(3)

1.6 T-Square …(3)

1.7 Set Square …(3)

1.8 Protactor …(4)

1.9 Compass …(4)

1.10 Dividers …(5)

1.11 Drawing Pencil …(5)

1.12 French Curves …(5)

1.13 Layout of a Drawing Sheet …(6)

Chapter 2 LINES, LETTERING AND DIMENSIONING 09 – 21

2.1 Lines : [IS 10714 (Part 20) : 2001 and SP46 : 2003] …(9)

2.2 Lettering [IS 9609 : 2001] …(10)

2.3 Dimensioning [IS 11669 : 1986] …(11)

2.4 Methods of Dimensioning …(12)

2.5 Arrangement of Dimensions …(13)

2.6 Dimensioning of Various Objects …(13)

2.7 Symbols and Abbreviations Used in Dimensioning …(15)

2.8 General Rules of Dimensioning …(15)

Contents (v)

Chapter 3 GEOMETRICAL CONSTRUCTIONS 22 – 26

3.1 Introduction …(22)

3.2 Basic Geometrical Shapes …(22)

Chapter 4 SCALES 27 – 34

4.1 Introduction …(34)

4.2 Representative Fraction (R.F.) …(27)

4.3 Units of Length and their Conversion …(28)

4.4 Types of Scales …(28)

Chapter 5 ENGINEERING CURVES 35 – 62

5.1 Introduction …(35)

5.2 Conic Sections or Conics …(35)

5.3 Special Curves …(42)

5.4 Plane Curves …(42)

5.5 Space Curves …(56)

Chapter 6 THEORY OF PROJECTIONS 63 – 74

6.1 Introduction …(63)

6.2 Projejction Methods …(63)

Chapter 7 PROJECTIONS OF POINTS 75 – 83

7.1 Introduction …(75) 7.2 Locations of a Point …(76) 7.3 Summary …(81)

Chapter 8 PROJECTIONS OF LINES 84 – 99

8.1 Introduction …(84) 8.2 Bis Conventions for Projection of Lines …(84)

8.3 Different orientation of lines and their projections …(84)

8.4 Traces of a line …(94)

8.5 Auxiliary Plane Projection Method …(95)

Chapter 9 PROJECTION OF PLANES 100 – 106

9.1 Introduction …(100)

9.2 Orientation of Planes and their Projections …(100)

Chapter 10 PROJECTIONS OF SOLIDS 107 – 119

10.1 Introduction …(107) (vi) Contents

10.2 Right Solid …(107)

10.3 Frustums and Truncated Solid …(108)

10.4 Orientation of Solid and their Projections …(109)

10.5 Suspended Solids …(112)

10.6 Section of Solids …(113)

10.7 Intersection of Surfaces of Solids …(114)

Chapter 11 DEVELOPMENT OF SURFACES 120 – 134

11.1 Introduction …(120)

11.2 Methods of Development of Lateral Surfaces …(121)

11.3 Isometric Projection …(128)

Engineering Design 135-186

Chapter 1 INTRODUCTION 135 – 141

1.1 Types of Engineering Design …(135)

1.2 Importance of Engineering Design …(136)

1.3 The Design Process …(136)

Chapter 2 CONCEPTUAL DESIGN 142 – 158

2.1 Introduction …(142)

2.2 Problem Definition …(142)

2.3 Gather Information …(148)

2.4 Concept Generation …(148)

2.5 Evaluation Method …(154)

Chapter 3 EMBODIMENT DESIGN 159 – 163

3.1 Introduction …(159)

3.2 Product Architecture …(159)

3.3 Configuration Design …(162)

3.4 Parametric Design …(162)

Chapter 4 DETAIL DESIGN 164 – 164

4.1 Introduction …(164)

4.2 Product Lifecycle Management (PLM) …(164)

Contents (vii)

Chapter 5 PROBLEM-SOLVING TOOLS 164 – 175

5.1 Introduction …(164)

5.2 Problem Definition …(165)

5.3 Cause Finding …(166)

5.4 Solution Planning and Implementation …(168) Engineering Safety 187-237

Chapter 1 INTRODUCTION 187 – 191

1.1 Safety …(187)

1.2 What is an Accidents …(187)

1.3 Accident Causation Theories …(188)

Chapter 2 HAZARD AND HAZARD ANALYSIS 191 – 199

2.1 Introduction …(191)

2.2 Hazard Analysis Methods and Techniques …(192)

2.3 Hazard Control …(198)

Chapter 3 RISK ANALYSIS AND MANAGEMENT 199 – 203

3.1 Risk Management …(199)

3.2 Risk Analysis Process and Methods …(201)

3.3 Role of ‘it’ in Health and Safety Management …(202)

3.4 Social Dimension of Risk-Contemporary Thinking …(202)

3.5 Evaulating Risk in Design …(202)

3.6 Risk Control Measures …(203)

Chapter 4 HUMAN FACTORS IN SAFETY 203 – 206

4.1 Job Stress …(203)

4.2 Occuptational Stressors and Workplace Stress Effects …(203)

4.3 Physical Stress Influencing Factors …(204)

4.4 Human Operator’s Stress Characteristics …(204)

4.5 Worksite Analysis Program for Human Factors …(205)

Chapter 5 SAFETY MANAGEMENT PRINCIPLES 206 – 213

5.1 Introduction …(206)

5.2 Safety Management Principles …(207)

5.3 Responsibilities Non-Safety Managers …(208) (viii) Contents

5.4 Safety Committees …(208)

5.5 Improving the Workplace Ergonomics …(209)

5.6 Safety Audit …(210)

5.7 Safety Survey …(212)

5.8 Emergency Preparedness and Response Planning (EPRP) in Major Accident Hazard Factories …(212)

Chapter 6 INITIATIVES TOWARDS SAFETY – GOI 213 – 221

6.1 Existing Set-up of Occupational Safety and Health in the Workplace in India …(213)

6.2 Government Bodies Dealing with OSH Regulations …(214)

6.3 National Level Autonomous Bodies/Organizations Connected with Occupational Safety & Health …(215)

6.4 12th Five Year Plan Schemes in Respect to Safety …(216)

6.5 Existing Scenario of Occupational Safety and Health in Various Segments of Unorganised Sector …(217)

6.6 Relevant Legislation in India …(220)

Chapter 7 MISCELLANEOUS 222 – 223

7.1 Occupational Health Problem …(222)

7.2 International Labour Organization …(223)

7.3 OSHA [Occupational Safety and Health Administration] …(223)

GLOSSARY 224-228

INTRODUCTION TO ENGINEERING DRAWING | 7

Questions

Choose the most appropriate answer out of the given 7. A typical layout of a drawing sheet does not alternatives : contain (a) centering mark 1. A drafter helps in drawing (b) orientation mark (a) parallel and perpendicular lines (c) trimming marks (b) concentric circles (d) identification mark (c) smooth curves 8. Grid references on a drawing sheet provide (d) all the above the following information:

2. In the engineering system of paper sizes, which (a) Location of details, additions, modifications, of the following is “A2” size? revisions, etc. of drawing (a) 841 mm × 1189 mm (b) To facilitate the positioning of the drawing (b) 594 mm × 841 mm when reproduced (c) 420 mm × 594 mm (c) To facilitate brief record and initials of the person responsible (d) 210 mm x 297 mm (d) To facilitate trimming 3. Which of the following pencil leads is hardest? 9. “A” series of paper has length-to-width ratio of (a) HB (b) H approximately (c) B (d) F (a) 3:2 (b) 3 :1 4. Which of the following purposes is not served by dividers? (c) 2 :1 (d) 5:3

(a) Divide lines or curves into a number of 10. The number of orientation marks generally equal parts contained by a drawing sheet is (b) Transfer measurement from one part of (a) one (b) two the drawing to another part (c) three (d) four

(c) Make full size, reduced size or enlarged 11. Extension arms are used with engineering size drawing compasses to (d) Step-off a series of equal distances on (a) draw circles of larger diameter the drawing (b) increase the gripping arm

5. To draw smooth curves of any nature, the (c) adjust distance between the legs draughting instrument used is (d) increase accuracy

(a) mini-drafter (b) French curve 12. Which of the following statements are correct? (c) templates (d) eraser shield I. The length of A2 size drawing sheet is equal to the width of Al size drawing 6. Parallel lines can be drawn with the help of sheet. (a) mini-drafter II. For technical drawing, harder grades of (b) T-square pencils are preferred. (c) pair of set squares (a) only I (b) Only II (d) all of these (c) Both (d) None 8 | ENGINEERING DRAWING

13. Which of the following statements are correct? (a) large compass

I. A D2 size drawing board has dimensions (b) bow pencil compass of 920 mm x 650 mm. (c) circle template II. A title block is placed at bottom right (d) any of the above corner of the drawing frame. 15. A French curve is used to draw (a) only I (b) Only II (c) Both (d) None (a) polygons (b) circles 14. To draw a circle of diameter 20 mm, the most preferred instrument is (c) ellipses (d) smooth freeform curves

ANSWER KEY

1. (a) 4. (c) 7. (d) 10. (b) 13. (b) 15. (d)

2. (c) 5. (b) 8. (a) 11. (a) 14. (b)

3. (b) 6. (d) 9. (c) 12. (c)

EXPLANATIONS

12. (c) A title block is placed at bottom right corner of the drawing frame and it is divided into two Length of A2 size drawing = 594 mm. zones. Width of A1 size drawing sheet = 594 mm (i) Part identification zone Hence, given statement is true. (ii) Additional information zone. For technical drawing, three grades of pencils 14. (b) are used. Those are H, 2H, HB. All these are hard grades pencils. Bow compasses are suitable to draw circles or arcs using pencil. To draw a circle of 13. (b) diameter smaller than 25mm bow pencil compass is preferred. A D2 size drawing board has dimensions of 650 mm × 470 mm. The given size in the 15. (d) question is of D1 drawing board. French curves is used to draw smooth freedom curves.