MANUFACTURING TECHNOLOGY (ME-405) - Important Questions

Explain centreless grinding with neat sketch, covering working principle, applications, advantages and limitations

Explain the nomenclature (tool signature) of a single point cutting tool with neat sketches.

Explain the different ways / causes of failure of cutting tools with neat sketch.

Write short notes on the superfinishing processes: honing, lapping, electro-polishing and buffing

In orthogonal straight turning of a cylindrical bar with given cutting velocity, feed, depth of cut and specific cutting energy, neglecting feed force contribution, find the main (tangential) cutting force.

Explain the properties, comparative evaluation and applications of various cutting tool materials (HSS, carbides, ceramics, CBN, diamond).

Explain the analysis, classification, working principle and industrial applications of various machining processes.

Explain the complete machining process from cutting tool selection to finishing operation. Discuss the factors affecting machining quality and productivity.

Find the breakeven cutting speed above which the carbide tool gives higher tool life than the HSS tool given $VT^n=C$ equations, with justification.

Explain the elements, construction and working of a surface grinding machine with a neat sketch, along with its applications, advantages/merits and limitations.

Explain the cutting action of a broach and describe the continuous surface broaching machine and the type of component surfaces for which it is useful.

Explain the mechanisms / reasons why cutting fluids are used and how they improve machining performance

What is gear hobbing and how does it work, with advantages and limitations?

Explain the principle of gear shaping operation, with advantages and disadvantages.

Compare form cutting versus gear generation with respect to their principles.

What is a DP cutter and what are the characteristics of DP cutters used for involute gear cutting?

List the various gear finishing methods and explain any four of them.

Explain the principle of operation of gear hobbing and gear shaving processes.

Explain the elements/terminology of a gear with a neat diagram.

Describe gear machining by generation method.

Explain hobbing and shaping processes with neat sketch.

Explain the injection moulding process with a neat sketch, including construction, working principle and industrial applications.

Explain the calendaring process with a neat sketch.

What is welding of plastics? Explain it along with its advantages and limitations.

Differentiate between the product developed by transfer moulding and extrusion moulding in all the aspects.

Explain the extrusion (molding) process for thermoplastic materials with a neat sketch, covering construction, working principle, advantages and applications.

Discuss the importance of plastic processing techniques in modern manufacturing industries. Explain their role in the automobile, aerospace, packaging, electrical, and medical sectors.

Explain the different types of moulds used in injection moulding and their benefits.

Illustrate with a sketch the blow molding process for producing plastic bottles.

Attempt the following

What is welding of plastics? Explain / write short note on it.

Explain the process of compression moulding with neat diagram.

Define blow moulding and explain its advantages and defects.

Explain the process/working principle and procedure of electrochemical machining (ECM) with diagram, along with its advantages and limitations.

Explain the construction and working of Electron Beam Machining (EBM) with diagram, including its advantages and applications.

Describe the characteristics of electron beam machining and discuss its advantages and limitations.

Define Unconventional Machining Processes, explain their need, classification and applications in modern manufacturing.

Describe the construction and working of ultrasonic machining (USM) with neat sketch and explain its industrial applications.

Discuss applications of Unconventional Machining Processes in aerospace, automobile, biomedical, electronics and precision manufacturing industries.

Define Non-Destructive Testing (NDT) and explain its objectives, advantages, and importance in inspection of machined components and cutting tools.

Compare Destructive Testing and Non-Destructive Testing with examples, advantages, disadvantages, and industrial applications.

Explain the working principle / construction of ultrasonic machining (USM) with a neat sketch showing important elements.

Explain the construction, working principle and applications of plasma arc machining.

Explain the working principle of EDM with a neat sketch, including need for unconventional machining, advantages and disadvantages

Explain the principle of abrasive water jet machining (AWJM) with a neat sketch and describe factors for selecting the abrasive.

Explain the construction / constructional features and working of an NC machine tool with block diagram.

Explain the working principle of the extrusion process with its advantages, disadvantages and industrial applications.

Define extrusion and differentiate between hot extrusion and cold extrusion processes with examples, covering aspects such as surface finish, mechanical properties, materials used and equipment.

Define sawing and explain its principles and importance in manufacturing industries.

Write the CNC part program for milling / machining center for the given part geometry (dimensions in mm).

Explain the difference between NC and CNC machines and discuss the coordinate systems used in NC machines.

What is NC part programming? Explain working of an NC machine tool with diagram along with advantages and limitations.

Sketch and describe band saw and circular saw.

Describe the types of metal flow occurring in extrusion and explain their importance.

What are the different types of control systems in Numerical Control?

Explain the concept of adaptive control of NC machines and list G-code and M-code functions.

Explain the tube extrusion process along with neat sketch. Write a short note on following:

A hole of 100 mm is to be punched in a cold rolled medium carbon steel plate of 5.6 mm thickness. The ultimate shear strength of plate material is 550 MPa. With normal clearance of 10% on the press tool, cutting is completed at 40% penetration of the punch. Calculate the die for the punch and die required for the purpose. If the shop has press of 30 tonnes capacity. Calculate the shear angle to be provided on the punch in order to bring the work within the capacity of the existing press.

Drive the following expression for pressure distributions (for sliding friction) for forging of a rectangular block (b $\times$ h $\times$ w) and show the variation $$\frac{p}{2K} = e^{\frac{-2\mu\left(x-\frac{b}{2}\right)}{h}}$$ where $p$ is the pressure at a distance $x$ from centre, K is shear strength of material and $\mu$ is the coefficient of sliding friction, $h$ is the height and $b$ the width.

Explain in detail the working of friction welding with neat sketch.

Define weldability of material and the factors on which weldability depends.

What do you understand by yield criteria for ductile materials? Find out the relation between Von Mises and Tresca's yield criteria.

How does a compound die differ from a progressive die? Giving a neat sketch describe constructional features.

Describe the process for bending a strip making allowance for its spring back. Sketch V-bending die and U-bending die.

Explain the principle and mechanism of rolling process. Give classification of rolling mills.