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BT-106 · Manufacturing Practices/Important Questions

Manufacturing Practices (BT-106) - Important Questions

  1. Unit 17 Marks High Priority

    Define and classify manufacturing processes. Describe the main groups of processes with examples and typical applications (e.g., casting, forming, machining, joining, additive manufacturing).

    Core overview of manufacturing process classifications; tests candidate's ability to distinguish process families and their applications.

  2. Unit 214 Marks High Priority

    Explain the sand casting process with a neat sketch. Describe all main steps in sequence and discuss at least five common casting defects along with their causes and remedies.

    Fundamental casting process question requiring sketch, process steps and discussion of typical defects and remedies; central to Unit 2.

  3. Unit 27 Marks High Priority

    Explain the forging process. Distinguish between open die and closed die forging and list typical applications and advantages of forging over casting.

    Core forging topic: differentiation between open and closed die forging, process steps and applications; frequently examined.

  4. Unit 310 Marks High Priority

    Describe the working principle, equipment, advantages and limitations of the following welding processes: Manual Metal Arc Welding (MMAW), Gas Metal Arc Welding (GMAW/MIG), and Tungsten Inert Gas (TIG) welding. Compare them with respect to deposition rate, quality and typical applications.

    Comparative question on welding processes; tests understanding of multiple arc and gas welding techniques and their practical trade-offs.

  5. Unit 37 Marks High Priority

    List and explain common welding defects (e.g., porosity, undercut, lack of fusion, cracks). For each defect give possible causes and remedial measures. Briefly describe two non-destructive testing (NDT) methods used to detect welding defects.

    Defects and inspection in welding plus introduction to non-destructive testing methods; a staple Unit 3 question.

  6. Unit 410 Marks High Priority

    Explain the mechanics of metal cutting for orthogonal cutting. Define chip thickness ratio $r$ and rake angle $\alpha$, and state the relation for the shear angle $\phi$ in orthogonal cutting. Give the equation for shear angle as: $$\tan\phi = \frac{r\cos\alpha}{1 - r\sin\alpha}$$ Explain the significance of each term.

    Fundamental metal-cutting theory question; includes Merchant shear-angle relation and interpretation of chip formation parameters.

  7. Unit 47 Marks High Priority

    State Taylor's tool life equation and explain the significance of its constants. The equation is given by: $$VT^{n} = C$$ where $V$ is cutting speed, $T$ is tool life, $n$ and $C$ are constants. Discuss how this equation is used to select cutting speeds.

    Tool life and machining parameter relation; Taylor's equation is core to cutting tool performance assessment.

  8. Unit 47 Marks Medium Priority

    Describe common lathe operations including turning, facing, threading and knurling. Sketch the tool nomenclature and show the typical single-point cutting tool geometry with principal angles.

    Lathe operations and tooling; tests practical knowledge of conventional turning operations and tool geometry.

  9. Unit 410 Marks Medium Priority

    Explain the principle of milling and distinguish between up milling and down milling. Define cutting speed $V$ and feed per tooth $f_z$, and give formulas to compute spindle speed $N$ and table feed $F$ for a given cutter diameter and number of teeth.

    Milling fundamentals including up vs down milling and machining parameter calculations; practical Unit 4 topic.

  10. Unit 57 Marks High Priority

    Explain the working, least count and typical errors of the following instruments: vernier caliper, micrometer screw gauge and gauge blocks. Describe the concept of calibration and traceability briefly.

    Precision measurement instruments and basics of calibration; essential for inspection and metrology (Unit 5).

  11. Unit 57 Marks Medium Priority

    Describe the basic components of a CNC machine and explain the part programming fundamentals. Explain coordinate system conventions and the difference between G-code and M-code instructions.

    CNC basics and part-programming fundamentals; rising importance in modern manufacturing (Unit 5).

  12. Unit 55 Marks Low Priority

    List and explain key safety practices in a manufacturing shop floor. Include personal protective equipment (PPE), safe handling of tools and materials, and basic hazard control measures.

    Workplace safety principles specific to manufacturing shop environment; often asked in short-answer form.

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