ME-405 Manufacturing Technology - Nov 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
   aDiscuss the various types of chips produced during metal machining with neat diagram.
   How to answer

   • Define chip formation in metal cutting
   • Describe continuous, discontinuous, continuous with built-up edge chips with conditions
   • Explain factors: material, speed, feed, rake angle, lubrication
   • Neat labelled diagrams of chip types
2. 7 Marks
   bSummarize the surface grinding process with a neat sketch and list out its merits.
   How to answer

   • Describe surface grinding principle and setup
   • Explain working with neat sketch of wheel, workpiece, table
   • List merits: surface finish, accuracy, hard materials
   • Mention applications
3. 7 Marks
   aExplain with neat sketches the following operation: Buffering and Super Finishing.
   How to answer

   • Define buffing: loose abrasive on cloth wheel for lustre
   • Define superfinishing: controlled low pressure honing with oscillation
   • Explain setups with neat sketches
   • Compare purpose, material removal and finish achieved
4. 7 Marks
   bDescribe gear machining by generation method.
   How to answer

   • Define gear generation principle: conjugate action of cutter and blank
   • Describe gear shaping / hobbing generation method
   • Explain relative motions of cutter and blank
   • List advantages and applications
5. 7 Marks
   aExplain the process of compression moulding with neat diagram.
   How to answer

   • Define compression moulding for thermosetting plastics
   • Describe mould, charge loading, heating, pressing and curing steps
   • Provide neat labelled diagram of press and mould
   • List applications and merits
6. 7 Marks
   bWhat do you mean by welding of plastics? Explain.
   How to answer

   • Define welding of plastics: joining by heat and pressure
   • Describe methods: hot gas, friction, ultrasonic, resistance
   • Explain process conditions for thermoplastics
   • Give applications
7. 7 Marks
   aCompare the electro discharge machining with electron beam machining with respect to their Process parameters.
   How to answer

   • Define EDM and EBM principles briefly
   • Compare on basis of energy source, material removal, accuracy, MRR
   • Compare process parameters: voltage, current, vacuum, beam power
   • Conclude suitability for applications
8. 7 Marks
   bExplain the process of electrochemical machining along with its advantages and limitations.
   How to answer

   • Explain ECM principle: anodic dissolution and Faraday's laws
   • Describe setup: tool, workpiece, electrolyte, power supply
   • List advantages: no tool wear, complex shapes, stress-free
   • List limitations: power consumption, electrolyte handling, cost
9. 7 Marks
   aIllustrate with neat sketch, about working principle of ultrasonic machining.
   How to answer

   • Define ultrasonic machining principle: abrasive slurry with ultrasonic vibration
   • Describe components: transducer, horn, tool, abrasives
   • Explain material removal with neat sketch
   • List applications and limitations
10. 7 Marks
    bList any five motion control statements of computer assisted NC programming and explain each step in detail.
    How to answer

    • Define NC motion control statements / G-codes
    • List any five: rapid traverse, linear interpolation, circular interpolation, dwell, etc.
    • Explain function and format of each statement
    • Give example block for each
11. 7 Marks
    aGive in detail classification of extrusion process. Mention advantages and limitations of each process.
    How to answer

    • Define extrusion and its classification: direct, indirect, impact, hydrostatic
    • Explain each process with sketches
    • Mention advantages of each process
    • Mention limitations of each process
12. 7 Marks
    bDifferentiate hot extrusion and cold extrusion.
    How to answer

    • Define hot and cold extrusion with temperature range
    • Differentiate on basis of temperature, force, finish, accuracy
    • Compare advantages and limitations
    • Give examples of products
13. 7 Marks
    aExplain with neat sketch hobbing and shaping.
    How to answer

    • Define hobbing: hob as rotating cutter generating gear teeth
    • Define shaping: reciprocating cutter generating teeth
    • Explain working with neat sketches
    • List applications
14. 7 Marks
    bDescribe gear finishing by shaping and list the advantages and disadvantages shaping process.
    How to answer

    • Describe gear finishing by shaping process
    • Explain cutter and blank motions
    • List advantages: accuracy, versatility
    • List disadvantages: slow, costly, limited size
15. 7 Marks
    aWith a neat sketch, explain injection moulding process and its applications.
    How to answer

    • Define injection moulding for thermoplastics
    • Explain hopper, screw, heater, mould clamping and ejection with sketch
    • Describe cycle steps
    • List applications: toys, containers, automotive parts
16. 7 Marks
    bBriefly explain the following with neat sketches:

    1. i)Orthogonal Cutting
    2. ii)Oblique Cutting
    How to answer

    • Define orthogonal cutting: edge perpendicular to cutting velocity
    • Define oblique cutting: edge inclined to cutting velocity
    • Explain with neat sketches showing angles and chip flow
    • Compare characteristics