ME-405 Manufacturing Technology - Jun 2023 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
   aExplain the elements, working of surface grinding machine giving a neat sketch and applications, advantages and limitations.
   How to answer

   • List main elements: base, table, wheel head, spindle, coolant system
   • Explain working: reciprocating table, grinding wheel rotation, downfeed
   • Provide neat sketch with labels
   • State applications, advantages and limitations
2. 7 Marks
   bExplain in detail the specifications of grinding wheel.
   How to answer

   • Define grinding wheel specification system
   • Explain abrasive type, grain size, grade, structure, bond
   • Explain standard marking sequence with example
   • Mention selection factors
3. 7 Marks
   aHow does wheel dressing differ from wheel truing?
   How to answer

   • Define wheel dressing: exposing sharp grains
   • Define wheel truing: restoring shape and concentricity
   • Compare purpose, tools and procedure
   • Give examples of when each is done
4. 7 Marks
   bExplain the, working of Centre less grinding with a neat sketch and applications, advantages and limitations.
   How to answer

   • Describe centreless grinding setup: grinding wheel, regulating wheel, work rest
   • Explain working with through-feed
   • Provide neat sketch
   • State applications, advantages and limitations
5. 7 Marks
   aExplain construction and working of Plasma arc machining and its applications.
   How to answer

   • Describe plasma generation and torch construction
   • Explain working with gas flow and arc
   • Provide schematic diagram
   • List applications in cutting and machining
6. 7 Marks
   bExplain construction and working of Electron beam machining and its applications.
   How to answer

   • Describe electron gun, vacuum chamber, focusing system
   • Explain beam generation and material removal
   • Provide schematic diagram
   • List applications for drilling and welding
7. 7 Marks
   aExplain in detail the working of friction welding with neat sketch.
   How to answer

   • Define friction welding principle: heat by friction
   • Describe stages: rotation, friction, upsetting
   • Provide neat sketch of setup
   • Mention weld characteristics
8. 7 Marks
   bDefine weldability of material and the factors on which weldability depends.
   How to answer

   • Define weldability of material
   • List metallurgical and process factors
   • Explain effect of carbon equivalent, thermal conductivity
   • Mention tests for weldability
9. 7 Marks
   aWhat do you understand by yield criteria for ductile materials? Find out the relation between Von Mises and Tresca's yield criteria.
   How to answer

   • Define yield criteria for ductile materials
   • State Von Mises distortion energy theory
   • State Tresca maximum shear stress theory
   • Derive relation between them under plane stress
10. 7 Marks
    bHow does a compound die differ from a progressive die? Giving a neat sketch describe constructional features.
    How to answer

    • Define compound die vs progressive die
    • Compare operations performed in one stroke
    • Provide neat sketch of both
    • Describe constructional features
11. 14 Marks
    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.
    How to answer

    • Calculate punching force from shear strength and area
    • Apply clearance 10% to find punch and die sizes
    • Check against 30 tonnes press capacity
    • Calculate shear angle needed to reduce load
12. 14 Marks
    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.
    How to answer

    • Consider slab equilibrium in forging with sliding friction
    • Set up differential equation for pressure gradient
    • Integrate to get $p/2K = e^{-2\mu(x-b/2)/h}$
    • Plot variation of pressure from centre to edge
13. 7 Marks
    aDescribe the process for bending a strip making allowance for its spring back. Sketch V-bending die and U-bending die.
    How to answer

    • Explain bending process and spring-back concept
    • Describe bend allowance calculation
    • Sketch V-bending and U-bending dies
    • Explain compensation for spring-back
14. 7 Marks
    bExplain the principle and mechanism of rolling process. Give classification of rolling mills.
    How to answer

    • Explain rolling principle: reduction by compressive forces
    • Describe mechanism: friction, bite, deformation zone
    • Classify rolling mills: two-high, three-high, four-high etc.
    • Give sketches of mill types