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BT-106 · Manufacturing Practices/Important Questions

Manufacturing Practices (BT-106) - Important Questions

  1. Unit 57 Marks High Priority

    Define metrology. Explain the different types of errors encountered in measurements (systematic error, random error and gross error) and discuss methods to detect and minimize each type.

    Fundamental concept frequently examined; tests understanding of measurement principles and error mitigation.

  2. Unit 510 Marks High Priority

    Explain limits, fits and tolerances. For a shaft and hole assembly with nominal size 50 mm, hole tolerance \(+0.04\) / \(0.00\) mm and shaft tolerance \(+0.02\) / \(-0.01\) mm, calculate the maximum clearance and minimum clearance. Show the procedure clearly.

    Core numerical problem frequently asked in examinations involving limits and fits calculations.

  3. Unit 57 Marks High Priority

    Describe the construction and working principle of a vernier caliper and a micrometer. If a vernier caliper has 10 vernier divisions equal to 9 mm, calculate its least count. If a micrometer has 50 divisions on the spindle corresponding to 25 mm, calculate its least count.

    Basic instrument knowledge and simple calculation; commonly asked to test measurement skills.

  4. Unit 57 Marks Medium Priority

    Explain the working principle and typical applications of a dial indicator. Describe the differences between mechanical comparators and electronic comparators and cite examples where each is preferred.

    Practical instrument application question; often appears in short/medium answer sections.

  5. Unit 57 Marks Medium Priority

    Define surface roughness parameters Ra and Rz and explain how they differ. Describe instruments used to measure surface finish and outline the procedure to measure Ra using a contact profilometer.

    Surface quality is an important inspection topic; both conceptual and instrument-related questions occur.

  6. Unit 55 Marks High Priority

    Describe the design and use of plug gauges, ring gauges and snap gauges. Explain the principle of GO and NO-GO gauges and give examples of their application in production inspection.

    Gauging and acceptance tests are core to manufacturing practice exams; GO–NOGO concept is fundamental.

  7. Unit 510 Marks Medium Priority

    Describe the working principle of a Coordinate Measuring Machine (CMM). Explain different probing methods, sources of measurement error in CMMs and typical applications in part inspection.

    Coordinate measurement is a modern inspection topic; medium priority for theory and application questions.

  8. Unit 55 Marks Medium Priority

    Explain the purpose and procedure of calibration of measuring instruments. Define traceability and describe why calibration certificates and traceability to national standards are important in a manufacturing environment.

    Calibration and traceability are recurring conceptual topics in quality systems questions.

  9. Unit 57 Marks Low Priority

    Discuss optical methods used in inspection such as optical comparators, profile projectors and interferometry. Explain one application where optical inspection is preferred over contact measurement.

    Optical inspection methods are less frequent but important for specialized inspections and surface evaluation.

  10. Unit 510 Marks High Priority

    Explain the purpose of control charts in Statistical Process Control (SPC). Define process capability indices and write the formulas for \(C_p\) and \(C_{pk}\). Show the formulas using LaTeX and explain each term in the formulas.

    Statistical quality control and capability indices are high-value topics combining statistics with inspection and are often asked.

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