06 ME 45 USN IV Sem B E Examination

MANUFACTURING PROCESS - II [ Common to ME / IP / IM / AU / MA ]

MODEL QUESTION PAPER Time: 3 Hrs.] [Max. Marks: 100 Note : Answer any five full Questions, choosing at least 2 Questions from each part.

1

a)

b)

2

a) b)

PART A Explain the following with a neat sketch i) Side relief angle ii) Rake angle iii) End & side cutting edge angle iv) Clearance angle In an experiment on an orthogonal cutting a chip length 95 mm was obtained from an uncut chip 0 length of 225 mm while cutting with a tool of 20 C rake angle using a depth of cut of 0.5 mm. Determine the shear plane angle, friction angle and chip thickness, if the horizontal and vertical component of cutting force are 1200 N and 360 N respectively.

(8)

(6)

(6)

c)

What are the main characteristics a cutting tool material should posses. Mention the effects of adding following alloying elements in tool materials. Also mention approximate percentage of each element. i) Carbon ii) Chromium iii) Tungsten Explain the three zones of heat generation in metal cutting.

3

a) b) c)

With a neat sketch explain the turret indexing mechanism. Describe the working and construction of a crank quick return mechanism of a shaper. What are the main operations performed on a planner? Explain.

(6) (8) (6)

4

a) b)

Give the detailed classification of drilling machine. With a neat sketch explain the following operations which are performed on drilling machine. i) Reaming ii) Internal Thread cutting Four holes are to be drilled through a steel plate of 20 mm thick. Diameter of the hole is 15 mm. Drilling is carried out at a cutting speed of 25 m/min and feed of 0.1 mm/rev. Assuming approach and over travel to be 3 mm each, calculate the machining time for all the four holes.

(6) (8)

c)

(6) (8)

PART B 5

a) b)

c)

Differentiate between up milling and down milling operations A C50 steel flat surface of 100X250 mm is to be produced on a horizontal axis milling machine. A HSS slab mill of 100 mm diameter and 150 mm width is to be used for the purpose. The milling cutter has 8 teeth. Calculate the machining time assuming that the entire stroke can be removed in one depth of 2 mm. Take cutting speed as 20 m/min and feed 0.13 mm/teeth. Show the calculation for indexing 111 division in a milling machine. The following index plate are available. Plate No. 1 Plate No. 2 Plate No. 3

15 21 37

16 23 39

17 27 41

18 29 43

19 31 47

(4) (8)

20 33 49

6

a) b) c)

What are natural and artificial abrasives? Why are latter preferred over the former? Write a note on dressing and truing of grinding wheel. Explain the factors to be considered while selecting a grinding wheel.

(6) (06) (8)

7

a) b)

(6)

c)

What are the purposes of lapping and horning? What are the governing parameters of lapping process? Discuss the influence of those parameters. How honing is done. How does it differ from lapping process? Discuss.

(6)

a) b)

With a neat sketch, the operations of ECM. List its industrial applications With a neat sketch, explain the working principle of abrasive jet machining. States its advantages.

(10) (10)

8

(8)

06 ME 45 USN IV Sem B E Examination

MANUFACTURING PROCESS - II [ Common to ME / IP / IM / AU / MA ]

MODEL QUESTION PAPER Time: 3 Hrs.] [Max. Marks: 100 Note : Answer any five full Questions, choosing at least 2 Questions from each part. PART A 1

a)

b)

2

3

4

Explain the following with a neat sketch i) Side relief angle ii) Rake angle iii) End & side cutting edge angle iv) Clearance angle In an experiment on orthogonal cutting a chip length of 95 mm was obtained from all 0 uncut chip length of 225 mm while cutting with a tool of 20 rake angle arising a depth of cut of 0.5 mm. Determine the shear plane angle, friction angle, chip thickness if horizontal & vertical components of cutting force are 1200 N and 360 N respectively.

a) b)

What are desirable properties of cutting tool material? Discuss the salient features of coated carbides and ceramics. Comment on their suitability as cutting tool materials.

a) b)

Describe the constructional features of a turret lathe. How in it different from an engine lathe. Draw a tool layout for hexagonal headed bolt in a capstan lathe.

a) b)

Sketch and explain the nomenclature of a twist drill. Explain any five operations carried in drilling machine using simple sketch.

(8)

(12)

(8) (12)

(12) (8) (10) (10)

PART B 5

a)

b) c)

6

a)

b)

Differentiate between i) Up and down milling ii) Peripheral and face milling iii) Simple and differential indexing Write a brief note on end milling cutters. With a neat sketch explain the principle of operation of dividing head attachment used on milling machine.

(9)

Differentiate between i) Plunge cut and traverse grinding ii) In-feed and through feed grinding Discuss the advantages and limitations of the centre less grinding operations.

(12)

(20)

7

a)

Explain the following with sketches i) Honing ii) Lapping

8

a)

With a neat sketch, explain the working principle of abrasive jet machining. State its advantages and limitations. Explain with a neat sketch ECM process. state its industrial applications and advantages

b)

(3) (8)

(08)

(10) (10)