ME-405 Manufacturing Technology - Dec 2024 Question Paper

Under each question, How to answer lists the points an answer should cover, outlined by CampusPrep from the syllabus. Check the details against your textbook.

1. 7 Marks
   aTwo cutting tools are being compared for a machining operation. The tool life equations are: Carbide tool : $VT^{1.6} = 3000$ HSS tool : $VT^{0.6} = 200$ Where $V$ is the cutting speed in m/min and $T$ is the tool life in min. The carbide tool will provide higher tool life if the cutting speed in m/min exceeds what value. Try to justify your statement.
   How to answer

   • Write Taylor tool life equations for carbide and HSS
   • Equate tool lives to find break-even cutting speed V
   • Solve $V^{1.6}/3000^{1/1.6}$ vs $V^{0.6}$ to get threshold value
   • Justify carbide gives higher life only above threshold speed
2. 7 Marks
   bWhat are the mechanisms that are generally responsible for the effectiveness of cutting fluid in improving machining performance?
   How to answer

   • Define role of cutting fluid in machining
   • Explain cooling, lubrication and chip removal mechanisms
   • Explain penetration and boundary lubrication at tool-chip interface
   • Relate to reduced friction, temperature and tool wear
3. 7 Marks
   aWhat are the difference between gear production and gear generation? Compare between them.
   How to answer

   • Define gear production/forming vs gear generation
   • Explain principle of each with examples
   • Compare on accuracy, tooling, productivity and application
   • Summarize in tabular form
4. 7 Marks
   bExplain the principle of gear shaping operation. Write the main advantages of gear shaping.
   How to answer

   • Explain gear shaping as generation process with pinion cutter
   • Describe reciprocating and rotary motions
   • List main advantages like internal gears, versatility
   • Add neat sketch of setup if needed
5. 7 Marks
   aWhat are the different types of moulds used in injection moulding? Explain their benefits.
   How to answer

   • List types: two-plate, three-plate, hot runner moulds
   • Explain construction of each briefly
   • Explain benefits like cycle time, gating, material saving
   • Suitability for different products
6. 7 Marks
   bExplain Calendaring process along with neat sketch.
   How to answer

   • Define calendaring for sheets/films
   • Describe roll arrangement and material flow
   • Explain temperature and thickness control
   • Provide neat labelled sketch
7. 7 Marks
   aExplain the need for the use of unconventional machining processes compared to the conventional ones.
   How to answer

   • Define limitations of conventional machining
   • List need: hard materials, complex shapes, surface integrity
   • Explain low cutting forces, no burr, high accuracy aspects
   • Give examples of applications
8. 7 Marks
   bBriefly explain the working of an USM machine, by showing important elements in a neat sketch.
   How to answer

   • Define USM principle with abrasive slurry and ultrasonic vibration
   • List elements: transducer, concentrator, tool, slurry system
   • Explain material removal by abrasive hammering
   • Provide neat sketch with labelled parts
9. 7 Marks
   aExplain construction and working of Plasma Arc Machining and its applications.
   How to answer

   • Describe plasma generation with torch construction
   • Explain working with gas flow, arc and material removal
   • List process parameters and capabilities
   • Give applications in cutting and coating
10. 7 Marks
    bWrite a short note on Laser Beam Machining.
    How to answer

    • Define LBM principle with stimulated emission
    • Describe setup: laser source, lenses, worktable
    • List process characteristics and limitations
    • Give applications
11. 7 Marks
    aExplain the difference between NC and CNC machines. Discuss the coordinate systems used in NC machines.
    How to answer

    • Define NC vs CNC with control and flexibility
    • Compare on programming, accuracy, cost and automation
    • Discuss Cartesian, polar and incremental/absolute systems
    • Summarize in table
12. 7 Marks
    bWhat is NC part programming? Explain the working of a NC machine tool with the help of a diagram. Also write advantages and limitations of NC machines.
    How to answer

    • Define NC part programming and program structure
    • Explain working of NC machine tool with block diagram
    • List advantages like repeatability and complex shapes
    • List limitations like cost and skilled manpower
13. 7 Marks
    aWhat is the working principle of extrusion process? Write its application, advantages and disadvantages.
    How to answer

    • Define extrusion with billet, die and ram
    • Explain direct vs indirect working principle
    • List applications like tubes, sections
    • Discuss advantages, disadvantages
14. 7 Marks
    bWrite the part program for machining centers (milling) of the given geometry. All dimensions are in mm. (Figure 1).

    

    How to answer

    • Interpret Figure 1 geometry: 60 SQ plate with slot
    • Define datum, tools and G/M codes for milling
    • Write step-wise part program with coordinates and feeds
    • Include safety and end commands
15. 7 Marks
    aWhat are the different types of control systems in Numerical Control?
    How to answer

    • Define need for control systems in NC
    • List point-to-point, straight-cut and contouring systems
    • Explain open-loop vs closed-loop
    • Give examples of each
16. 7 Marks
    bExplain the tube extrusion process along with neat sketch. Write a short note on following:

    1. i)Power hacksaw
    2. ii)Band Saw
    How to answer

    • Explain tube extrusion with mandrel/die and neat sketch
    • Describe material flow and hollow section formation
    • Write short notes on power hacksaw working
    • Write short notes on band saw working