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BT-106 · Manufacturing Practices/Important Questions

Manufacturing Practices (BT-106) - Important Questions

  1. Unit 17 Marks High Priority

    Explain the classification of manufacturing processes. Give examples and typical applications for each class.

    Core theory: classification and overview of manufacturing processes; fundamental for Unit 1 concepts and frequently appears in exams.

  2. Unit 17 Marks High Priority

    Describe the geometry and nomenclature of a single point cutting tool. Explain the significance of rake angle, clearance angle and cutting edge radius on cutting performance.

    Core practical concept from metal cutting theory; common question on tool geometry and its effect on machining.

  3. Unit 210 Marks High Priority

    Derive expressions for cutting speed $V$, spindle speed $N$, feed $f$ and material removal rate $Q$. Use the relation $$V = \frac{\pi D N}{1000}$$ and show how $Q$ is related to $f$, depth of cut and width of cut.

    Standard derivation/problem involving machining parameters; frequently set as numerical/derivation question.

  4. Unit 37 Marks High Priority

    List and describe common welding defects. For each defect explain the probable causes and suggest remedies.

    Core welding theory: common question on defects and remedies; important for practice and inspection topics.

  5. Unit 310 Marks High Priority

    Explain the principles, advantages, limitations and typical applications of SMAW, MIG (GMAW) and TIG (GTAW) welding processes.

    Fundamental comparison of major arc welding processes; frequently asked for differences and applications.

  6. Unit 410 Marks High Priority

    Describe the sand casting process with a neat flow of steps. Explain the role of pattern, mold, core and gating system. List typical casting defects and their causes.

    Core foundry process question; sand casting steps and defect discussion are standard exam topics.

  7. Unit 57 Marks High Priority

    Explain the following heat treatment processes: annealing, normalizing, quenching and tempering. State the purpose and typical effects on microstructure and mechanical properties.

    Heat treatment fundamentals are core to materials processing and commonly questioned for definitions and effects.

  8. Unit 27 Marks Medium Priority

    Discuss tool materials used in machining such as high speed steel, cemented carbide and ceramics. Explain the need for coatings on cutting tools and mention common coating materials.

    Materials and tooling is a core practical topic; questions often ask for comparison and selection criteria.

  9. Unit 510 Marks High Priority

    Explain the concepts of limits, fits and tolerances. Define basic hole system and basic shaft system. Illustrate with examples of clearance, interference and transitional fits.

    Metrology and limits/fits is a standard topic; usually asked for definitions and example calculations.

  10. Unit 27 Marks Medium Priority

    Describe the basic components of a CNC machine and explain the role of G-codes and M-codes in part programming. Give examples of commonly used G-codes.

    CNC fundamentals and part programming basics are increasingly important; exam pattern includes short theory and simple programming questions.

  11. Unit 47 Marks Medium Priority

    Describe the powder metallurgy process flow from powder production to compaction and sintering. Mention typical applications where powder metallurgy is preferred.

    Powder metallurgy is an elective/advanced manufacturing topic; occasionally appears as a short question.

  12. Unit 110 Marks High Priority

    Explain the working principles, process steps and typical applications of bulk metal forming processes such as rolling, forging and extrusion. Discuss factors affecting forming operations.

    Metal forming processes are fundamental manufacturing operations and commonly asked in exams.

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