ME-405 Manufacturing Technology - Jun 2022 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
   aWhat are the four different ways for failure of cutting tools? Explain with neat sketch.
   How to answer

   • Define tool failure modes: flank wear, crater wear, plastic deformation, chipping/breakage
   • Explain mechanism for each with causes
   • Neat sketch showing flank and crater wear on tool
   • Effect on surface finish and tool life
2. 7 Marks
   bA cylindrical bar of 100 mm diameter is orthogonally straight turned with cutting velocity, feed and depth of cut of 120 m/min, 0.25 mm/rev and 4 mm, respectively. The specific cutting energy of the work material is $1\times 10^3$ J/m$^3$. Neglect the contribution of feed force towards cutting power. Find the main or tangential cutting force (in N).
   How to answer

   • Material removal rate $MRR = V \cdot f \cdot d$
   • Cutting power $P = u \cdot MRR$ where $u$ is specific energy
   • Tangential force $F_c = P/V$
   • Substitute values and compute $F_c$ in N
3. 14 Marks
   Two 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 $VT^n = C$ for both tools
   • Equate tool life $T$ to find break-even $V$
   • Solve $V^{1.6}/3000 = V^{0.6}/200$ for $V$
   • Justify carbide better above break-even due to lower n effect
4. 14 Marks
   Writes down about the super finishing processes given below in brief:

   1. i)Honing
   2. ii)Lapping
   3. iii)Electro polishing
   4. iv)Buffing
   How to answer

   • Define superfinishing purpose - low roughness, high accuracy
   • Brief principle, tool/medium and application of honing
   • Brief principle of lapping, electro-polishing, buffing
   • Comparison of finish achievable
5. 7 Marks
   aWhat is gear hobbing and how does it work? Write the Advantages and Limitations of Gear Hobbing Process, with neat sketch.
   How to answer

   • Define gear hobbing - generating process with hob cutter
   • Working principle with rotation and feed relations
   • Neat sketch of hob and gear blank setup
   • Advantages and limitations list
6. 7 Marks
   bWhat are the difference between gear production and gear generation? Compare between them.
   How to answer

   • Define gear production vs gear generation concepts
   • Explain forming vs generating principles
   • Compare on accuracy, tooling, productivity, cost
   • Examples of each method
7. 7 Marks
   aDefine hot extrusion and cold extrusion Process on the basis of surface finish, mechanical properties, material used and machine specification.
   How to answer

   • Define hot extrusion and cold extrusion with temperature range
   • Compare surface finish, mechanical properties, materials
   • Compare machine tonnage and tooling specification
   • Applications of each
8. 7 Marks
   bWhat is blow moulding? What are the advantage and Defects of Blow Moulding?
   How to answer

   • Define blow moulding principle with parison and air pressure
   • Steps: extrusion of parison, clamping, blowing, ejection
   • Advantages for hollow parts
   • Typical defects: wall thickness variation, flash, warpage
9. 7 Marks
   aWrite down the short note on welding of plastics. What are the Advantage and limitation of the technology?
   How to answer

   • Define plastic welding methods: hot gas, ultrasonic, friction etc.
   • Brief procedure and materials weldable
   • Advantages: light weight joints, no fasteners
   • Limitations: joint strength, material compatibility
10. 7 Marks
    bDifferentiate between the product developed by transfer moulding and extrusion moulding in all the aspects.
    How to answer

    • Define transfer moulding and extrusion moulding principles
    • Compare process, mould, product shapes, materials
    • Compare on all aspects: cost, rate, finish, size
    • Typical products for each
11. 7 Marks
    aDraw the logical diagram of electrochemical machining, and describe the procedure, working principle, advantage and limitation of the process.
    How to answer

    • Draw logical/block diagram of ECM cell: tool, workpiece, electrolyte, power supply
    • Explain working principle - anodic dissolution, Faraday's law
    • Procedure steps and process parameters
    • Advantages and limitations
12. 7 Marks
    bWhat is the characteristics of electron beam machining, write the advantage and limitation of the EBM.
    How to answer

    • Define EBM with high velocity electron beam in vacuum
    • Characteristics: high energy density, vacuum, precision
    • Advantages for micro-machining hard materials
    • Limitations: cost, vacuum, safety, MRR
13. 14 Marks
    Writes the part program for machining centers (milling) for the given geometry. All dimensions are in mm.

    

    How to answer

    • Interpret Figure 1: 50 SQ plate, 15 mm thick, slot 30x10 with R5
    • Select datum, tools, speeds/feeds and coordinate system
    • Write milling sequence: facing, slotting, finishing
    • Give complete part program with G/M codes