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2 General Principles of Design, Drawing & Safety New Pattern for UPSC ESE Exam Office : F-126, (Lower Basement), Katwaria Sarai, New Delhi Phone : Mobile : , info@iesmasterpublications.com, info@iesmaster.org Web : iesmasterpublications.com, iesmaster.org

3 IES MASTER PUBLICATION F-126, (Lower Basement), Katwaria Sarai, New Delhi Phone : , Mobile : , info@iesmasterpublications.com, info@iesmaster.org Web : iesmasterpublications.com, iesmaster.org All rights reserved. Copyright 2017, by IES MASTER Publications. No part of this booklet may be reproduced, or distributed in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise or stored in a database or retrieval system without the prior permission of IES MASTER, New Delhi. Violates are liable to be legally prosecuted. First Edition : 2016 Second Edition (Revised) : 2017 Typeset at : IES Master Publication, New Delhi

5 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

6 CONTENTS Section Description Page No. Preface (iii) Engineering Drawing Chapter 1 INTRODUCTION TO ENGINEERING DRAWING Introduction (1) 1.2 Drawing Sheets : [IS : 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 Lines : [IS (Part 20) : 2001 and SP46 : 2003] (9) 2.2 Lettering [IS 9609 : 2001] (10) 2.3 Dimensioning [IS : 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)

8 Contents (v) Chapter 3 GEOMETRICAL CONSTRUCTIONS Introduction (22) 3.2 Basic Geometrical Shapes (22) Chapter 4 SCALES 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 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 Introduction (63) 6.2 Projejction Methods (63) Chapter 7 PROJECTIONS OF POINTS Introduction (75) 7.2 Locations of a Point (76) 7.3 Summary (81) Chapter 8 PROJECTIONS OF LINES 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 Introduction (100) 9.2 Orientation of Planes and their Projections (100) Chapter 10 PROJECTIONS OF SOLIDS Introduction (107)

9 (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 Introduction (120) 11.2 Methods of Development of Lateral Surfaces (121) 11.3 Isometric Projection (128) Engineering Design Chapter 1 INTRODUCTION Types of Engineering Design (135) 1.2 Importance of Engineering Design (136) 1.3 The Design Process (136) Chapter 2 CONCEPTUAL DESIGN 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 Introduction (159) 3.2 Product Architecture (159) 3.3 Configuration Design (162) 3.4 Parametric Design (162) Chapter 4 DETAIL DESIGN Introduction (164) 4.2 Product Lifecycle Management (PLM) (164)

11 Contents (vii) Chapter 5 PROBLEM-SOLVING TOOLS Introduction (164) 5.2 Problem Definition (165) 5.3 Cause Finding (166) 5.4 Solution Planning and Implementation (168) Engineering Safety Chapter 1 INTRODUCTION Safety (187) 1.2 What is an Accidents (187) 1.3 Accident Causation Theories (188) Chapter 2 HAZARD AND HAZARD ANALYSIS Introduction (191) 2.2 Hazard Analysis Methods and Techniques (192) 2.3 Hazard Control (198) Chapter 3 RISK ANALYSIS AND MANAGEMENT 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 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 Introduction (206) 5.2 Safety Management Principles (207) 5.3 Responsibilities Non-Safety Managers (208)

12 (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 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) th 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 Occupational Health Problem (222) 7.2 International Labour Organization (223) 7.3 OSHA [Occupational Safety and Health Administration] (223) GLOSSARY

14 Questions INTRODUCTION TO ENGINEERING DRAWING 7 Choose the most appropriate answer out of the given alternatives : 1. A drafter helps in drawing (a) (b) (c) (d) parallel and perpendicular lines concentric circles smooth curves all the above 2. In the engineering system of paper sizes, which of the following is A2 size? (a) (b) (c) (d) 841 mm 1189 mm 594 mm 841 mm 420 mm 594 mm 210 mm x 297 mm 3. Which of the following pencil leads is hardest? (a) HB (b) H (c) B (d) F 4. Which of the following purposes is not served by dividers? (a) (b) (c) (d) Divide lines or curves into a number of equal parts Transfer measurement from one part of the drawing to another part Make full size, reduced size or enlarged size drawing Step-off a series of equal distances on the drawing 5. To draw smooth curves of any nature, the draughting instrument used is (a) mini-drafter (b) French curve (c) templates (d) eraser shield 6. Parallel lines can be drawn with the help of (a) (b) (c) (d) mini-drafter T-square pair of set squares all of these 7. A typical layout of a drawing sheet does not contain (a) (b) (c) (d) centering mark orientation mark trimming marks identification mark 8. Grid references on a drawing sheet provide the following information: (a) (b) (c) (d) Location of details, additions, modifications, revisions, etc. of drawing To facilitate the positioning of the drawing when reproduced To facilitate brief record and initials of the person responsible To facilitate trimming 9. A series of paper has length-to-width ratio of approximately (a) 3:2 (b) 3 : 1 (c) 2 : 1 (d) 5:3 10. The number of orientation marks generally contained by a drawing sheet is (a) one (b) two (c) three (d) four 11. Extension arms are used with engineering compasses to (a) (b) (c) (d) draw circles of larger diameter increase the gripping arm adjust distance between the legs increase accuracy 12. Which of the following statements are correct? I. The length of A2 size drawing sheet is equal to the width of Al size drawing sheet. II. For technical drawing, harder grades of pencils are preferred. (a) only I (b) Only II (c) Both (d) None

15 8 ENGINEERING DRAWING 13. Which of the following statements are correct? I. A D2 size drawing board has dimensions of 920 mm x 650 mm. II. A title block is placed at bottom right corner of the drawing frame. (a) only I (b) Only II (c) Both (d) None 14. To draw a circle of diameter 20 mm, the most preferred instrument is (a) large compass (b) bow pencil compass (c) circle template (d) any of the above 15. A French curve is used to draw (a) polygons (b) circles (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) 13. (b) Length of A2 size drawing = 594 mm. Width of A1 size drawing sheet = 594 mm Hence, given statement is true. For technical drawing, three grades of pencils are used. Those are H, 2H, HB. All these are hard grades pencils. A D2 size drawing board has dimensions of 650 mm 470 mm. The given size in the question is of D1 drawing board. A title block is placed at bottom right corner of the drawing frame and it is divided into two zones. (i) (ii) 14. (b) 15. (d) Part identification zone Additional information zone. Bow compasses are suitable to draw circles or arcs using pencil. To draw a circle of diameter smaller than 25mm bow pencil compass is preferred. French curves is used to draw smooth freedom curves.

General Principles of

General Principles of Design, Drawing & Safety New Pattern for UPSC ESE Exam Office : F-126, (Lower Basement), Katwaria Sarai, New Delhi-110016 Phone : 011-26522064 Mobile : 8130909220, 9711853908 E-mail: