Manufacturing Practices (BT-106) - Important Questions

Explain the core principles of Joining methods including welding and brazing.

Explain the mechanics of orthogonal cutting. Derive the relationships for cutting forces and cutting power, and explain the concept of specific cutting energy.

State Taylor's tool life equation and explain how cutting speed, feed and depth of cut influence tool life. Given $V\,T^{n}=C$, show how to calculate the new cutting speed required to achieve a specified tool life.

Describe the working principles, advantages, limitations and typical applications of the following additive manufacturing processes: Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA).

Compare and contrast traditional subtractive manufacturing processes with additive manufacturing methods with respect to material utilization, achievable geometric complexity, production rate and typical industrial applications.

Explain the sand casting process. Sketch and describe each main step, list common materials used for moulds and cores, and discuss typical casting defects with their remedies.

Differentiate between die casting and investment casting in terms of process steps, achievable tolerances and surface finish, typical advantages and limitations, and give typical applications of each.

Explain the principles of bulk forming operations: forging, rolling and extrusion. For each process discuss the main process parameters, typical product forms and common defects with control measures.