Manufacturing Process-II - Jun 2015

Mechanical Engg (Semester 6)

TOTAL MARKS: 100
TOTAL TIME: 3 HOURS (1) Question 1 is compulsory.
(2) Attempt any four from the remaining questions.
(3) Assume data wherever required.
(4) Figures to the right indicate full marks.

Answer any one question from Q1 and Q2

1 (a) Explain lapping process with neat sketch.(6 marks) 1 (b) A plain surface 60 mm wide and 230 mm long is to be milled on a horizontal milling machine with cutter diameter 80 mm and speed 50 m/min. Take feed per tooth is 0.11 mm and number of teeth on cutter = 12. Calculate machining cutter.(6 marks) 10 (a) List various types of clamping devices used in jig and fixtures. Explain any one in detail.(6 marks) 10 (b) Explain concept of Poka Yoke in jig and fixture.(4 marks) 10 (c) Design and draw milling fixture for milling slot of 10 mm wide, 5 mm deep and 20 mm in length for the component shown in fig. (a) (8 marks) 2 (a) Draw figure of any four grinding wheel shapes used, with its names.(6 marks) 2 (b) Draw and explain broach tool geometry.(6 marks)

Answer any one question from Q3 and Q4

3 (a) A 250 mm diameter bar is turned at 40 rev/min. with depth of cut of 2 mm and feed of 0.3 mm/rev. Calculate Power consumption and specific cutting energy with cutting force 1500 N and Feed force 400 N.(4 marks) 3 (b) Explain economics of machining in metal cutting.(4 marks) 4 (a) Draw neat sketch of single point cutting tool geometry.(4 marks) 4 (b) Define built up edge. With neat sketch explain formation of BUE.(4 marks)

Answer any one question from Q5 and Q6

5 (a) Explain LBM process with its adv., limitations and applications.(8 marks) 5 (b) Compare the ECM and USM with various process parameters.(8 marks) 6 (a) Draw a Schematic diagram of 'Electro-discharge Machining' and explain its working principle and process parameters.(8 marks) 6 (b) Explain AJM process with its advantages, limitations and applications.(8 marks)

Answer any one question from Q7 and Q8

7 (a) Explain CNC machines with neat sketch. State its advantages and limitations.(6 marks) 7 (b) Differentiate between subroutine and canned cycle.(4 marks) 7 (c) Write a CNC program for manufacturing component shown in fig. From a 100 mm long cylindrical component of 80 mm dia. (6 marks) 8 (a) Write short notes on the following:
i) Machining Center.
ii) Automatic tool changer (ATC)(8 marks) 8 (b) Differentiate between absolute and incremental positioning system in CNC.(4 marks) 8 (c) Explain the following codes G02, M06, G04, M09.(4 marks)

Answer any one question from Q9 and Q10

9 (a) What is 3-2-1 location principle? Explain with the help of neat sketches.(6 marks) 9 (b) What are the different types of jigs? Explain any one with suitable sketch.(4 marks) 9 (c) Design and draw drilling jig for drilling the two 10 mm dia. holes in the component shown in fig. (a)(8 marks)