KPSC Assistant Engineer (Mech) Syllabus 2024: Topics, Pattern, Books

The Kerala Public Service Commission (KPSC) has released the detailed syllabus for the Assistant Engineer (Mechanical Engineering) post in The Kerala Agro Industries Corporation Limited (Category No. 595/2024). This comprehensive syllabus outlines the topics covering various aspects of Mechanical Engineering, including core subjects and a significant portion dedicated to Agricultural Engineering, to prepare candidates for the 100-mark examination.

Syllabus Overview

Detailed Syllabus

The examination will cover the following subjects, with a total of 100 marks. Each main section of Mechanical Engineering carries 10 marks, while Agricultural Engineering is divided into 10 modules, each carrying 5 marks.

Industrial Management and Industrial Engineering (10 Marks)

• Principles of Management: Meaning of management–Taylor’s scientific management, Functions of management-Different types of ownership-organizational structure. Principles of a good Wage Payment System, minimum wages, Incentives. Quality Planning and its developments – Definitions, dimensions, and TQM concepts.
• Project Management Techniques: Commonly used terms in CPM and PERT, critical path, slack, or float, Comparison between CPM and PERT.
• Quantitative techniques in Management: Linear programming –formulation of LPP—transportation problem– Least cost method, North-West corner rule, Vogel’s approximation method.
• Inventory management – definition and classification – EOQ and ABC analysis. Sales – sales forecasting.
• Meaning of the terms production and productivity – types of production – Job production batch production, mass production, continuous production – Scheduling – Dispatching – Plant location and layout, Factors to be considered in locating industrial plants – Types of layouts.
• Method Study: Work study – Method study – Process chart symbols – operation process chart, flow process chart, man-machine chart, and SIMO chart, Principles of motion economy, Objectives of work measurement – Procedure of stop watch time study.
• Concept of quality and quality control, Control Charts introduction, types of control charts – X-bar, R, P, 100P and C.
• Fundamental Statistical Concepts: frequency, frequency distribution and frequency plot—Normal distribution curve – Explanation of the terms mean, mode, median and standard deviation.
• Project Analysis: Need and scope for project analysis-Explanation of the constituents elements of project analysis.

Metallurgy and Machine Tools (10 Marks)

• Metals and alloys: Structure of materials – Crystal structure –BCC, FCC and HCP – Ferrous and non-ferrous- Cast iron, Manufacturing of Pig iron – Blast Furnace – Manufacturing of Cast iron – Cupola Furnace – Types of steel – Manufacturing of steel, Steel alloys – Non ferrous metals and alloys-Aluminium, Copper and its alloys–Crucible furnace.
• Heat Treatment Processes: iron carbon equilibrium diagram – TTT diagram – Micro constituents of steel – Heat treatment process.
• Properties, testing and inspection of materials: Mechanical properties such as strength, hardness, toughness, brittleness, creep, fatigue, stiffness, ductility, malleability, elasticity and plasticity- Thermal properties such as specific heat, thermal conductivity, thermal resistance, and thermal diffusivity-Destructive tests and Non-destructive tests.
• Classification of measuring instruments – precision and non precision instruments – Direct reading and indirect measuring instruments, classifications of gauges, comparators.
• Principle of arc welding, selection of welding electrodes, Electrode coatings – Functions of electrode coating, Gas welding, submerged arc welding, tungsten inert gas (TIG) welding, metal inert gas (MIG) welding, Atomic hydrogen welding and thermit welding – Defects in welding – causes and remedies of the defects such as porosity, poor penetration, warping, under cut, distortion crack, poor appearances, soldering, brazing.
• Metal Cutting: Orthogonal cutting and oblique cutting, Tool life, Machinability.
• Type of lathes, Lathe accessories, Work holding and tool holding devices, Speed, feed and depth of cut – Operations – taper turning methods – Lathe specification.
• Drilling Machines: Classification–Work holding devices–Types of drill bits—Tool holding devices- Operations. Shaping Machines: Parts and their functions. Milling Machines: General use of milling machines-Parts of milling machines and their functions-types of milling machines, Milling operations, Types of indexing.
• Definition of jigs and fixtures.
• Grinding: Abrasives, Bonding materials, kinds of abrasives, functions of the grinding wheels.
• Flexible Manufacturing System: Flexible automation–flexible manufacturing cell – components of FMS. Computer Numerical Control (CNC).

Fluid Mechanics, Pneumatic and Hydraulic Machines (10 Marks)

• Properties of Fluids: Density-specific weight-specific volume-specific gravity – viscosity – Newton’s law of viscosity –types of fluids— compressibility – surface tension –capillarity.
• Fluid Pressure and its Measurement: Fluid pressure at a point– Pascal’s law – absolute, gauge, atmospheric and vacuum pressures, measurement of fluid pressure – pressure measuring devices.
• Types of fluid flow -steady and unsteady flow – uniform and non-uniform flow – laminar and turbulent flow – compressible and incompressible flow – rotational and irrotational flow – continuity of liquid flow – energy of a liquid in motion–Bernoulli’s equation—practical applications of Bernoulli’s equation.
• Impact of Jets: Force exerted by the jet, Impulse turbines – classification – Pelton wheel components. Reaction Turbines: Components – difference between impulse and reaction turbines, classification of Reaction Turbines, specific speed.
• Pumps: Types of pumps, centrifugal pumps – efficiencies – discharge – power required to drive – multi stagepumps- specific speedof CP -cavitation– priming. Reciprocating Pump – Types – comparison of CP & RP – discharge – slip – air vessels, Hydraulic ram.

Applied Mechanics, Strength of Materials and Design of Machine Elements (10 Marks)

• Direct Stresses and Strains: Types of Stresses and strains—tensile and compressive – longitudinal and lateral strain – Poisson’s ratio – stress strain diagram – limit of proportionality – elastic limit – yield point – ultimate stress – working stress – factor of safety – comparison of stress strain diagrams, principle of superposition – stresses in varying section – stresses in composite section. Shear stress and strain – modulus of rigidity -volumetric strain, bulk modulus. Nature and magnitude of stresses due to change in temperature.
• Introduction – type of friction – static friction, dynamic friction, sliding friction, rolling friction, pivot friction, limiting friction, angle of friction, coefficient of friction, cone of friction.
• Moment of inertia–radius of gyration.
• Joints: Riveted Joints – types—lap joint-single riveted, double riveted – failure of riveted joints, Welded Joints: Welding terms, strength of welded joints.
• Torsion equation – strength equation for solid and hollow shaft, power equation – polar moment of inertia.
• Springs: Types of spring–leaf spring–helical springs.
• Types of beams – cantilever beam, simply supported beam, overhanging beam, built in beam or fixed beam and continuous beam, types of loading, shear force and bending moment diagrams – maximum bending moment on the section. – deflection of beams. Column, strut, buckling load, equivalent length, slenderness ratio -types of columns—short column, medium size column, long column.
• Thread terminology – Forms of screw threads -Witworth thread, British Association thread, American standard thread –Acme thread–ISO metric thread-square thread-single start and multi start threads right hand and left hand threads – conventional representation of threads. Bolted connection using standard proportions.
• Limits, Fits and Tolerances: Definition of limits, fits and tolerances. Surface roughness terminology – surface roughness values.
• General design procedure – Design stress and working stress – factor of safety – Kinematic link – pair – chain – four bar chain – examples and applications– mechanism– inversion.
• Torsional stresses and strains – strength of solid and hollow shaft – design of shaft considering strength and rigidity – comparisons – power transmitted by shaft – solid and hollow shafts in terms of their weight, strength and stiffness. Shaft couplings-requirement-types.
• Functions of bearings – classification of bearings – Radial bearings – thrust bearings – sliding contact bearings – rolling contact bearings.
• Classification of followers and cams – motion of the followers – uniform velocity, simple harmonic motion – displacement diagrams.
• Governors and Flywheels: Functions of the governors – types of governors – flywheels – coefficient of fluctuation of energy.
• Gears and Gear Trains: Functions of gears – advantages and disadvantages of a gear drive – spur gear nomenclature – simple gear drive – velocity ratio – gear trains-simple gear train- compound gear train.

Thermal Engineering (10 Marks)

• Air Standard Cycles: Assumption, Air standard efficiency-explanation with diagrams and derivation of air standard efficiency of Carnot Cycle, Otto cycle, Diesel cycle, dual combustion cycle. Classification of fuels – solid, liquid and gaseous – requirements of a good fuel – Calorific Value -combustion of fuel.
• Performance of I. C. Engines – testing, Total fuel consumption and Specific Fuel Consumption – Morse test of multi-cylinder engines.
• Heat Transfer: Heat Transfer – conduction, convection and radiation – Fourier’s law – Thermal conductivity – Conduction through plane wall and composite wall –Black body concept – Stefan-Boltzman law – free and forced convection, Heat exchangers – Classification – regenerative type, parallel flow, counter flow type and cross flow, LMTD.
• Air Compressors: Construction and working of Air compressors – function of an air compressor – uses of compressed air – classification of the air compressors -working of reciprocating compressors (single stage and two stage), rotary compressors – fans and blowers, centrifugal compressors and axial flow compressors.
• IC Engine sub-systems: Fuel systems, ignition system, cooling system, lubrication system – quantity governing – quality governing-hit and miss governing.
• Definition of refrigeration, concept of C. O. P., unit of refrigeration-reversed Carnot cycle – COP, Application of refrigeration.
• Principles and working of a vapour compression system with the help of flow diagram. C.O.P. of vapour compression systems. Compressors – Condensers – Evaporators-Expansion Devices—capillary tube, Thermostatic expansion valve. Definition of refrigerants, primary and secondary refrigerants, desirable properties of refrigerants.
• Psychrometry – principles and uses, Sensible heating, sensible cooling–humidifying, dehumidifying. Definition of air conditioning, classification, factors affecting human comfort, effective temperature, working of summer air conditioning, winter and year round air-conditioning.

Agricultural Engineering (50 Marks)

This section is divided into 10 modules, each carrying 5 marks.

Module – I (5 Marks)

• Primary and secondary tillage operations -mould board plough, disc plough- functional component, accessories and attachments- chisel plough- subsoiler- horizontal and vertical suction of MB plough -forces acting on tillage implements- field efficiencies. Draft measurement of tillage implements and calculation of power requirement for tillage. Sowing, planting and weeding equipment. Seed drills and planters -types of seed metering mechanisms and furrow openers. Calibration and adjustments of seed drills and planters. Sprayers and dusters. types of nozzles.

Module – II (5 Marks)

• Harvesting- methods and technologies: Reapers (VCR), mowers and chaff cutters. Threshers: types of threshing drums- factors affecting thresher performance. Winnowers. Grain and straw Combines- computation of combine losses. Tractors and power tillers – engines -power transmission systems: clutch, gearbox, differential and final drives. Tractor power outlets- p.t.o power and drawbar power. Determination of maximum draw bar pull. Tractor tyres. Traction aids. Centre of gravity and moment of inertia of tractors.

Module – III (5 Marks)

• Hitching of implements – mounted, semi-mounted and trailed type implements. Traction mechanics: pull and draft, coefficient of traction, tractive efficiency and weight transfer. Calculation of field capacity and field efficiency- Economics of machinery usage, fixed cost, variable costs- estimating the cost of operation and break-even point.

Module – IV (5 Marks)

• Testing of tractors and farm machines: type of tests, test codes and procedure. Ergonomic considerations in designing farm machines – anthropometry and assessment of energy expenditure. Vibration and noise levels and its physiological effects. Non-conventional energy sources- solar thermal energy conversion- flat plate and concentrating collectors – solar constant photovoltaic electric production– PV systems.

Module – V (5 Marks)

• Wind energy conversion- power coefficient- Betz limit -Bio energy: thermo chemical energy conversion of biomass- biomass gasification- gasifiers – biochemical energy conversion of biomass: anaerobic digestion process – fixed and floating type bio gas plants-bio mass characteristics. Gasifier technology- types of gasifiers.

Module – VI (5 Marks)

• Soil properties influencing irrigation management- soil- water relations- infiltration characteristics of soil and equations -water requirement of crops. Mechanics and types of soil erosion- soil loss estimation -biological and engineering measures to control erosion- water harvesting structures. Estimation of mean rain fall. Measurement of run off – Cook’s method. Linear, aerial and relief aspects of watersheds -stream order. Watershed management: factors and measures. Hydrograph- applications and limitations.

Module – VII (5 Marks)

• Surveying: basic principles and classification. Levelling – rise and fall system, classification of levelling. Total station and GPS survey. Remote Sensing: basic components, advantages and limitations. Types of sensors and platforms. GIS: basic components, spatial data, map projections, data models and its integration. Properties of fluids- hydrostatic pressure and its measurement- Bernoulli’s theorem- laminar flow in pipes- general equation for head loss-Darcy’s equation- major and minor losses through pipes and fittings- open channel hydraulics-Chezy’s and Bazin’s formula- on farm structures for water conveyance- control and distribution-drop structures.

Module – VIII (5 Marks)

• Surface and sub surface drainage – coefficient- design parameters – hydraulic conductivity- drainable porosity – Hooghoudt’s spacing equations. Hydraulics of flow in wells- centrifugal pumps- total pumping head-NPSH- maximum suction lift- power requirement – performance curves. Sprinkler and drip irrigation systems- layout- hydraulic design of lateral sub-main and main pipe line- selection of pump.

Module – IX (5 Marks)

• Rheological properties- force deformation- stress- strain- elastic -plastic- and viscous behavior- drying – theory of grain drying- moisture content and water activity- free, bound and equilibrium moisture content. Equipment for cleaning and grading. Size reduction: fineness modulus- principles of comminution: laws and procedures, crushing, impact, cutting and shearing.

Module – X (5 Marks)

• Principles of processing and preservation: blanching and canning. Thermal processing of food – freezing, refrigeration and cold storage. Drying: hysteresis effect -EMC determination psychometric chart. Grain dryers – batch and continuous type -types of grain dryers: deep bed dryer- flat bed, continuous flow and LSU dryer. Storage of grains – improved storage structures: CAP, hermetic storage, pusabin, RCC ring bins.

NOTE: It may be noted that apart from the topics detailed above, questions from other topics prescribed for the educational qualification of the post may also appear in the question paper. There is no undertaking that all the topics above may be covered in the question paper.

Exam Pattern

The KPSC Assistant Engineer (Mechanical) exam will be for a total of 100 marks. The distribution of marks across various sections is as follows:

Note: The duration of the exam and details regarding negative marking are not explicitly mentioned in this syllabus notification. Candidates are advised to refer to the official exam notification or admit card for these specifics.

Recommended Books

Based on the detailed syllabus, here are highly recommended books for Assistant Engineer (Mechanical) preparation:

Note: These are standard recommended books. It is crucial to cover all topics mentioned in the official syllabus using these or similar comprehensive textbooks.

Preparation Strategy

Comprehensive Study Plan

• Understand the Syllabus: Thoroughly go through each topic in the syllabus, paying special attention to the weightage of Agricultural Engineering (50% of the total marks).
• Prioritize Topics: While all topics are important, dedicate more time to Agricultural Engineering and other high-weightage Mechanical Engineering sections.
• Conceptual Clarity: Focus on understanding fundamental concepts rather than rote memorization, especially for Fluid Mechanics, Thermodynamics, and Design.
• Practice Numerical Problems: Mechanical Engineering exams often include numerical questions. Practice solving problems from each topic to improve accuracy and speed.
• Revision: Regularly revise all subjects. Short notes and flashcards can be very helpful.
• Mock Tests: Attempt previous year’s question papers and mock tests to familiarize yourself with the exam pattern, time management, and identify weak areas.
• Time Management: Develop a study schedule that allocates sufficient time for each subject, including dedicated slots for revision and practice.

Daily Study Routine

Aim for 6-8 hours of dedicated study daily. Allocate morning hours for complex theoretical subjects or problem-solving when your mind is fresh. Distribute your time between Mechanical core subjects and Agricultural Engineering modules. Ensure short breaks to maintain focus and avoid burnout.

Important Topics

Given the syllabus breakdown, it is clear that Agricultural Engineering carries significant weight (50% of the total marks). Candidates must give utmost importance to all modules under this section. For the Mechanical Engineering core subjects, all five sections (Industrial Management, Metallurgy & Machine Tools, Fluid Mechanics, Applied Mechanics & Machine Design, Thermal Engineering) carry equal weightage of 10 marks each. Therefore, a balanced approach covering all these areas comprehensively is essential for success.

Frequently Asked Questions

Q1: Is there negative marking in the KPSC Assistant Engineer (Mechanical) exam?

A1: The official syllabus document does not explicitly mention details regarding negative marking. Candidates should refer to the detailed examination notification or their admit card for specific information on the marking scheme, including negative marking if any.

Q2: What is the significance of Agricultural Engineering in a Mechanical Engineering syllabus?

A2: For the Assistant Engineer post in The Kerala Agro Industries Corporation Limited, Agricultural Engineering is highly relevant as the corporation deals with agro-industrial activities. Mechanical engineers in such roles often work with farm machinery, post-harvest technology, and irrigation systems, making this a crucial part of the syllabus.

Q3: How important are numerical problems in this exam?

A3: Mechanical Engineering exams typically include a mix of theoretical and numerical questions. Topics like Fluid Mechanics, Strength of Materials, Thermal Engineering, and even parts of Agricultural Engineering (e.g., efficiency calculations) will likely have numerical problems. Practice is key for these.

Q4: Should I focus more on Mechanical Engineering core subjects or Agricultural Engineering?

A4: Since Agricultural Engineering accounts for 50% of the total marks, it is imperative to give it significant attention. However, the other five Mechanical Engineering sections combined also make up 50% of the marks. A balanced preparation strategy, ensuring strong command over both areas, is crucial for maximizing your score.

Q5: Where can I find previous year’s question papers for this exam?

A5: Candidates should regularly check the official KPSC website (keralapsc.gov.in) for previous year’s question papers or model questions for similar Assistant Engineer exams. Practicing these will give you a good understanding of the question format and difficulty level.

Q6: Are there any specific topics from the Mechanical Engineering degree that are not covered but might appear?

A6: The notification explicitly states: “It may be noted that apart from the topics detailed above, questions from other topics prescribed for the educational qualification of the post may also appear in the question paper.” This means while the provided syllabus is extensive, candidates should also have a general understanding of broader Mechanical Engineering concepts relevant to their degree, as some questions might originate from those areas.