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Subject Code: KME403

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BTECH
(SEM IV) THEORY EXAMINATION 2021-22
MANUFACTURING PROCESSES
 
Time: 3 Hours Total Marks: 100
Note: Attempt all Sections. If you require any missing data, then choose suitably.

SECTION A
1. Attempt all questions in brief. 2*10 = 20
Qno Questions CO
(a) What is shrinkage allowance in casting? 1
(b) Differentiate between open die forging and closed die forging? 1
(c) Differentiate between single point and multi point cutting tool. 2
(d) What are the advantaged of CNC over NC machines? 2
(e) What is meant by hardness of grinding wheel? 3
(f) Differentiate between dressing and truing process in grinding. 3
(g) What do you mean by straight polarity in arc welding? 4
(h) Differentiate between brazing and soldering process? 4
(i) What is the function of electrolyte in ECM? 5
(j) What are the applications of water jet machining? 5
90

2
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SECTION B
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2.
2. Attempt any three of the following: 10*3 = 30
P2

24
Qno Questions CO
2E

(a) Differentiate the hot working and cold working process. Justify which 1

5.
process is best suitable for wire drawing?
.5
P2

(b) What do you mean by taper turning operation? Explain any one 2
17
methods of taper turning with help of neat sketch.
Q

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(c) How are grinding wheels specified? Clearly differentiate between 3

grade and structure of a grinding wheel?
6

(d) Explain the working of atomic hydrogen welding with 4

4
1:

help of suitable diagram; also write down their specific

:3

applications and advantages and limitations?

13

(e) Write brief notes on all of the following : 5

(i) Electron beam Machining (EBM)
2

(ii) Ultrasonic Machining (USM)

02

(iii) Laser beam machining (LBM)

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08

SECTION C
3. Attempt any one part of the following: 10*1 = 10
6-

Qno Questions CO
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(a) Explain draft in rolling process. Show that the maximum draft is given 1
by
Where: µ is the coefficient of friction and R is the roll radius.
(b) Explain the solidification phenomena in casting. Also describe any five 1
casting defects and their remedies in brief.

4. Attempt any one part of the following: 10 *1 = 10

Qno Questions CO
(a) Explain Merchant’s force circle diagram and derive the merchant’s 2

QP22EP2_290 | 16-08-2022 13:31:46 | 117.55.242.132

 Printed Page: 2 of 2 
Subject Code: KME403
0Roll No: 0 0 0 0 0 0 0 0 0 0 0 0 0

BTECH
(SEM IV) THEORY EXAMINATION 2021-22
MANUFACTURING PROCESSES
 
shear angle relationship.
(b) The following equation for tool life was obtained for HSS tool. A 60 2
min tool life was obtained using the following cutting condition
VT0.13f0.6d0.3= C. v = 40 m/min, f = 0.25 mm, d = 2.0 mm. Calculate the
effect on tool life if speed, feed and depth of cut are together increased
by 25% and also if they are increased individually by 25%; where f =
feed, d = depth of cut, v = speed.

5. Attempt any one part of the following: 10*1 = 10

Qno Questions CO
(a) Show that maximum chip thickness tm in surface grinding, using 3
grinding wheel of diameter D, is given by
tm= 4𝑓/𝜋𝐷𝑟𝑔𝐶 ∗ 𝑑/𝐷 /
Where f = feed, C= No. of abrasive grains per unit area of grinding
wheel surface, d= depth of cut and rg is the ratio of grain width to uncut
thickness per grit.
(b) Write brief notes on all of the following 3
90

2
a) Honing

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b) Lapping

2.
c) Superfinishing
P2

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2E

5.
6. Attempt any one part of the following: 10*1 = 10
Qno Questions CO
.5
P2

17
(a) The voltage-length characteristics of a direct current (DC) arc is given 4
Q

by V= (20+40l) Volts, where l is the length of arc in mm. The power

|1

source characteristics is approximated by a straight line with an open

circuit voltage = 80 V and short circuit current = 1000 Amp. Determine
4 6

the optimum arc length and corresponding arc power?

1:

(b) Explain the principle of Resistance welding process. Discuss how heat 4
:3

balance is achieved in resistance spot welding?

13

7. Attempt any one part of the following: 10*1 = 10

2

Qno Questions CO
02

(a) What is Abrasive jet machining (AJM)? Describe its 5

-2

working with suitable diagram. Also explain the effect of

08

standoff distance and abrasive grit size on material

6-

removal rate in the AJM

(b) Explain the mechanics of material removal in ECM Processes. If 5
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current of 1500 amp is used, determine the volume rate of material

removal from the copper block. (Density of copper 8.96g/cm3, valency
1 and gram atomic weight as 58.93)

QP22EP2_290 | 16-08-2022 13:31:46 | 117.55.242.132