Birla Institute of Technology & Science, Pilani

Work-Integrated Learning Programmes Division

First Semester 2018-2019

Comprehensive Examination
(EC-3 Regular)

Course No. : ET ZC235

Course Title : MANUFACTURING PROCESSES
Nature of Exam : Open Book
Weightage : 40% No. of Pages =2
Duration : 3 Hours No. of Questions = 4
Date of Exam : 24/11/2018 (AN)
Note:
1. Please follow all the Instructions to Candidates given on the cover page of the answer book.
2. All parts of a question should be answered consecutively. Each answer should start from a fresh page.
3. Assumptions made if any, should be stated clearly at the beginning of your answer.

Q.1 (a) Explain the difference in the importance of drafts in green-sand casting vs. permanent
mold casting. [4]
Q.1 (b) In a surface-grinding operation, calculate the chip dimensions for the following
process variables: D = 8 in., d = 0.001 in., v = 30 ft/min, V = 5000 ft/min, C = 500 per
in2, and r = 20. [3]
Q.1 (c) Explain why the cutting force, Fc, increases with increasing depth of cut and
decreasing rake angle. [3]

Q.2 (a) Assume that in orthogonal cutting the rake angle is 150 and the coefficient of friction
is 0.2. Determine the percentage increase in chip thickness when friction is doubled.
[5]

Q.2 (b) (i) Differentiate between Drilling and Reaming. [3]

(ii) Why Drilling, boring, and reaming of large holes is generally more accurate than
just drilling and reaming? [1]
(iii) Why Negative rake angles are generally preferred for ceramic, diamond, and
cubic boron nitride tools? [1]

Q.3 (a) Explain

(a) Why ultrasonic machining is not suitable for soft and ductile metals?
(b) Why the same grinding wheel may act soft or hard?
(c) Why it is generally recommended that a soft-grade wheel be used for grinding
hardened steels?
(d) Why so many different welding processes have been developed?
(e) Similarities and differences between consumable and non-consumable
electrode arc welding processes. [5 x 1 = 5]

Q.3 (b) State the similarities and differences between [5 x 1 = 5]

(a) Casting Of Metals and Fusion Welding
(b) Resistance Seam Welding and Resistance Spot Welding
(c) Bolt and Rivet
(d) Properties of castings made by permanent mold vs. sand-casting methods
(e) Bulk-Deformation Processes and the Sheet-Metal Forming Processes

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Q.4 (a) Which of the advanced machining processes causes thermal damage to workpieces?
List and explain the possible consequences of such damage. [3]

Q.4 (b) A 25-mm-thick copper plate is being machined by wire EDM. The wire moves at a
speed of 1.5 m/min and the kerf width is 1.5 mm. Calculate the power required.
Assume density of copper is = 8970 kg/m3, and it takes 1550 J to melt one gram of
copper. [4]

Q.4 (c) Differentiate between Hard automation, Soft automation and adaptive control
manufacturing processes. [3]

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