Motor Vehicle Inspector, Grade-II

AUTOMOBILE ENGINEERING AND MECHANICAL ENGINEERING

(DIPLOMA STANDARD) SUBJECT CODE: 310
Section a : AUTOMOBILE ENGINEERING ( No. of Questions -100 : 150
Marks)
UNIT - I: MECHANICS OF MATERIALS:
Structure of metals - Ferrous alloys Non ferrous metals and alloys - Heat Treatment of
steel and surface heat treatment or case hardening - Toughening - Normalising –
refining-Mechanical properties of materials - Simple Stress and strain – Modulus of
elasticity- Shear force, Twist, Theory of simple bending, deflection.
UNIT – II: PRODUCTION TECHNOLOGY:
Foundry - Patterns - Casting Techniques - Welding - Drilling - boring and Jig boring
machines – Milling machines - Grinding machine - Cylinder Boring and honing machines.
Lathes - Gas welding - Arc welding Brazing and soldering.
UNIT – III: ELECTRICAL AND ELECTRONICS ENGINEERING:
Units and symbols - AC and DC - Electro magnetisms - EMF - DC Circuits - Battery types
Dry, Wet - DC Generators - DC Motors and Starters - Transistor - Capacitor - Diodes -
Rectifiers – circuit breakers, Electronic components - symbols.
UNIT – IV: BASICS OF MECHANICAL ENGINEERING:
Fluid mechanics : Properties of fluids - flow of fluids - Flow of fluids in closed conduits -
Reciprocating pumps - Centrifugal pump – Gear pumps and vane pumps - Hydraulic
systems – Thermal Engineering - Properties of Gases - Expansion of Gases - Air cycles –
Fuels- Fuel characteristics – Octane number and Cetane number – Lubricants Viscocity,
Flash point, Fire point and Pour point - Air compressors performance - IC Engine
performance.
UNIT – V: AUTOMOBILE ENGINES:
Principles of 2 stroke and 4 stroke engines - Engines Valve timing, - port timing - Valve
arrangements - Engine blocks - cylinder heads - Wet and dry liner - Pistons - connecting
rod - Crank shaft - Camshaft - timing gears - valve/ports - Firing order - Static balance –
Dynamic balance - cooling systems - Radiators - Lubricating system - Lubricating oil
characteristics Crank case ventilation - Engine testing/Fault finding, equipments -
Carburation and Carburettors – MPFI - Diesel Engine for Automobile purpose -
Combustion process of Diesel engines - Diesel knock – Diesel - combustion chamber
types – CRDI - Injectors types - Feed pumps - - Fuel Injection Pumps - Phasing and
Calibration - Governors' - Super charges and Turbo Chargers – EGR - Emissions Control
system in engines - Maintenance and servicing.
UNIT – VI: AUTOTRONICS:
Battery lead acid - types - capacity - coil ignition system - Magneto ignition system and
transistorised ignition system - ignition timing - spark plugs - starter motors -
Alternators – voltage and current regulator - cutout unit. Flasher unit - wiring looms -
circuits lighting - Auto cable – symbols.
UNIT – VII: TRANSMISSION AND CONTROLS:
Friction and Transmission of motion - Clutches - Gearboxes - Epicyclic gear box - Pre
selector gear box - universal joints - Differential - Floating axles. Constant velocity joints
– suspension system - independent front suspension systems - steering types - caster -
camber - toe in – toe out – power steering – types - wheel balancing - brakes - Testing
its efficiency – Anti-lock braking systems - Tyres - tubes - Types and maintenance-
Trouble shooting - Preventive Maintenance and servicing.
UNIT – VIII: INDUSTRIAL MANAGEMENT AND ROAD TRANSPORT
ORGANIZATION:
Leadership - Morale – Motivation - Production planning and control - Personnel -
Materials - Financial Management – Depreciation calculation using straight line method
and sinking fund method – ABC analysis. Goods Transport, Passenger transport,
Operational Layout of service station and garages - Bus stand - Classification -
passenger transport organization and Administrative set up. Motor Vehicle act - Road
signals - Traffic signals - Permit – Registering vehicle - Fitness certificate - Ticket
system. Study to improve services, Accident claim. Market research - costing in Road
transport Running cost.
UNIT – IX: BODY BUILDING TECHNOLOGY:
Terminology - classification of motor vehicle body - passenger transport - goods
Transport - Cars - Chassis - frame principle - Aerodynamic body considerations. Body
shape – NVH – definition - NVH elimination - Bus body construction. Goods vehicle
construction - Tanker, Tipper Constructions - Ergonomics of Driver seat design - Painting - Body
repairing - maintenance and safety on painting.
UNIT- X: COMPUTER INTEGRATED MANUFACTURING:
CAD – Definition – geometric modeling – wireframe, surface and solid modeling –
graphic
standards – GKS, IGES, PHIGS and DXF. CAM – definition – gropu technology – part
families – parts classification and coding – CAPP – types. CNC – definition – 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.
Section b: MECHANICAL ENGINEERING ( No. of Questions -100 : 150
Marks)
UNIT - I: INDUSTRIAL MANAGEMENT
X and Y theories of Management, Contributions of Henry Fayol and F.W. Taylor for Management -
job evaluation by Ranking method and factor comparison method - motivating techniques –
fixing selling price of a product - break even analysis for make or buy decision - sinking fund
method and straingt line method of calculating depreciation - ABC analysis – determination of
economic order quantity – TQM – ISO standards - certification
UNIT - II: INDUSTRIAL ENGINEERING:
Factors influencing plant location - principles of layout - techniques used to improve
layout - primary and secondary causes of an accident - personal protective devices -
method study procedure - flow diagram, string diagram and two handed process chart -
principles of motion economy-procedure for conducting stopwatch time study,
production study and ratio delay study - objectives of preplanning, routing, scheduling,
despatching and controlling - difference between inspection and quality control - types
of plant maintenance - TPM
UNIT - III: PRODUCTION TECHNOLOGY:
Foundry - patterns - special casting techniques - welding - hot and cold working –
drawing, rolling and forging - powder metallurgy - plastics - rubber - ceramics -
refractories - 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
UNIT - IV: ELECTRICAL AND ELECTRONICS ENGINEEERING:
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 – Electronics
– diodes – resisitors – capacitors – transistors – logic gates.
UNIT - V: MECHANICS OF MATERIALS:
Mechanical properties of metals - simple stresses and strains – modulus of elasticity –
geometrical properties of sections - thin cylinders bending moment and shear force - theory of
simple bending - torsion and springs - transmission of motion – gear drives and belt drives.
UNIT - VI: HEAT POWER ENGINEERING:
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 - working
principle of single and multistage compressors - Comparison of reciprocating and rotary
compressors - classification of steam boilers - construction and working of steam
turbines - working principle of steam power plant - Main elements of a nuclear power
plant - Vapour compression cycle - factors affecting human comfort - working principle
of a window air conditioner and central air conditioning system.
UNIT - VII: COMPUTER APPLICATIONS:
Working principle and constructional details of computer - classification of computer –
Input / Output devices - flow charting – MS Office & Star Office – creating documents –
presentations – sending emails.
UNIT - VIII: FLUID MECHANICS AND MACHINERY:
Working of differential manometer - use of venturimeter and orifice classification of
mouth pieces meter - working of pelton wheel, francis turbine and kaplan turbine -
construction and working principle of reciprocating pump, centrifugal pump and gear
pump - quick return mechanism of shaping machine - table movement in a milling
machine.
UNIT - IX: COMPUTER INTEGRATED MANUFACTURING:
CAD – Definition – geometric modeling – wireframe, surface and solid modeling –
graphic standards – GKS, IGES, PHIGS and DXF. CAM – definition – group technology –
part families – parts classification and coding – CAPP – types. CNC – definition –
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.
UNIT - X: DESIGN OF MACHINE ELEMENTS:
Factors affecting selection of material – classification of bearings – sliding contact and rolling
contact bearings – radial and thrust bearings – limits – fits – tolerance – classification of fits –
cams and followers – types.
Section c: General Studies ( No. of Questions -75 : 150
Marks)
1. GENERAL SCIENCE
i. Nature of Universe – Measurement of Physical Quantities – General Scientific
Laws in Motion – Force, Pressure and Energy – Everyday application of the basic
principles of Mechanics, Electricity, Magnetism, Light, Sound, Heat and Nuclear Physics
in our daily life.
ii. Elements and Compounds, Acids, Bases, Salts, Petroleum Products, Fertilizers,
Pesticides, Metallurgy and Food Adulterants.
iii. Main concepts of Life Science, Classification of living organisms, Evolution,
Genetics, Physiology, Nutrition, Health and Hygiene,Human diseases.
iv. Environmental Science.

2. CURRENT EVENTS
i. Latest diary of events – National symbols–Profile of states –Eminent
personalities and places in news–Sports –Books and Authors.
ii. Welfare Scheme of Government – Political parties and Political system in Tamil
Nadu and India.
iii. Latest inventions in Science and Technology – Geographical Land Marks –
Current Socio – Economic issues.
3. GEOGRAPHY
i. Earth Location – Physical Features – Monsoon, rainfall, weather and climate–
Water resources–Rivers –Soil, Minerals and Natural resources– Forest and Wildlife–
Agriculture pattern.
ii. Transport– Communication.
iii. Population density and distribution in Tamil Nadu and India.
iv. Calamities–Disaster Management–Environment – Climate change

4. HISTORY AND CULTURE OF INDIA

i. Indus Valley Civilization –Guptas, Delhi Sultans, Mughals and Marathas – South
Indian History.
ii. Characteristics of Indian Culture, Unity in Diversity–Race, Language, Custom.
iii. India as a Secular State.
5. INDIAN POLITY
i. Constitution of India–Preamble to the Constitution–Salient features of the
Constitution–Union, State and Union Territory.
ii. Citizenship, Fundamental Rights, Fundamental Duties, Directive Principles of
State Policy.
iii. Union Executive, Union Legislature–State Executive, State Legislature– Local
Governments, Panchayat Raj.
iv. Spirit of Federalism: Centre-State Relationships.
v. Election–Judiciary in India–Rule of Law.
vi. Corruption in public life – Anti-Corruption measures – Lokpal and Lokayukta –
Right to Information – Empowerment of Women – Consumer Protection Forums – Human
Rights Charter.

6. INDIAN ECONOMY
i. Nature of Indian economy–Five year plan models – an assessment – Planning
Commission and NITI Aayog.
ii. Sources of revenue–Reserve Bank of India – Finance Commission– Resource
sharing between Union and State Governments –Goods and Services Tax.
iii. Economic Trends – Employment Generation, Land Reforms and Agriculture –
Application of Science and Technology in Agriculture – Industrial growth – Rural Welfare
oriented programmes – Social Problems –Population, Education, Health, Employment,
Poverty.
7. INDIAN NATIONAL MOVEMENT
i. National Renaissance –Early uprising against British Rule–Indian National
Congress – Emergence of Leaders –[Link], Bhagat Singh, Bharathiar,
[Link], Thanthai Periyar, Jawaharlal Nehru, Rabindranath Tagore,
Kamarajar, Mahatma Gandhi, Maulana AbulKalam Azad, Rajaji, Subhash Chandra Bose,
Muthulaksmi Ammaiyar, Muvalur Ramamirtham and other National Leaders.
ii. Different modes of Agitation of Tamil Nadu and movements.
8. HISTORY, CULTURE, HERITAGE AND SOCIO-POLITICAL MOVEMENTS OF
TAMIL NADU
i. History of Tamil Society, related Archaeological Discoveries, Tamil Literature
from Sangam age till contemporary times.
ii. Thirukkural: a) Significance as a Secular Literature. b) Relevance to Everyday
Life. c) Impact of Thirukkural on Humanity. d) Thirukkural and Universal Values –
Equality, Humanism etc. e) Relevance to Socio – Politico –Economic affairs. f)
Philosophical content in Thirukkural.
iii. Role of Tamil Nadu in freedom struggle – Early agitations against British Rule –
Role of women in freedom struggle.
iv. Various Social reformers, Social reform movements and Social transformation
of Tamil Nadu.

9. DEVELOPMENT ADMINISTRATION IN TAMIL NADU

i. Social Justice and Social Harmony as the Cornerstones of Socio-Economic
Development.
ii. Education and Health systems in Tamil Nadu.
iii. Geography of Tamil Nadu and its impact on Economic growth

Section d: Aptitude & Mental Ability (No. of Questions -25: 50

Marks)
i. Simplification–Percentage–Highest Common Factor (HCF) – Lowest
Common Multiple (LCM).
ii. Ratio and Proportion.
iii. Simple Interest– Compound Interest–Area–Volume–Time and
Work.
iv. Logical Reasoning – Puzzles – Dice–Visual Reasoning–Alpha
Numeric Reasoning– Number Series.