Production Technology - May 2015

Mechanical Engineering (Semester 8)

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. 1 (a) How cutting tools are are classified? Name few tools of each type. What do you mean by chip with built up edge? What factors are responsible for this type of chip formation?(7 marks) 1 (b) Explain with neat sketch manufacturing of gear by Gear shaping using pinion type cutters. What are the advantages of this method?(7 marks) 2 (a) Differentiate between Jigs and Fixture. Enlist different types of clamping devices. Explain any two with neat sketches.(7 marks)

Answer any two question from Q2 (b) or Q2 (c)

2 (b) Explain with neat sketch the importance and functions of different tool angles associated with the geometry of a single point cutting tool.(7 marks) 2 (c) Write a short note on advance cutting tool materials along with its characteristics and applications.(7 marks)

Answer any two question from Q3 (a), (b) or Q3 (c), (d)

3 (a) In Orthogonal turning of a 50 mm diameter Mild steel bar on a lathe the following data were obtained. Rack angle = 15 degree ; cutting speed=100m/min, Feed = 0.2 mm / rev., Cutting force = 180 Kg, Feed Force=60 Kg, Calculate the shear plane angle, Coefficient of friction , Cutting power, the chip flow velocity and shear force, if the chip thickness = 0.3mm.(7 marks) 3 (b) What is transfer machine? List the essential component of a transfer machine and explain any two in detail.(7 marks) 3 (c) What are guide ways? What are the principal requirements of them? Enlist various types of guide ways used in machine tools. Explain any two in detail.(7 marks) 3 (d) Define tool life? What are Crater wear and flank wear. What are the factors responsible for them?(7 marks)

Answer any two question from Q4 (a), (b) or Q4 (c), (d)

4 (a) Draw a Merchant's Circle Diagram and derive expressions to show relationships amongst the different forces acting on the cutting tool and different parameter involved in metal cutting.(7 marks) 4 (b) It is required to make hexagonal head bolt on a capstan lathe from a hexagonal bar stock, draw tool layout for producing the required bolt on capstan lathe showing the operations oat different stations.(7 marks)

Answer the following:

4 (c) (i) Write short note on material utilization factor for a sheet metal on a press tool using press tool die.(3 marks) 4 (c) (ii) Coated cutting punch increase the life of punch. Discuss.(4 marks) 4 (d) Explain with neat sketches , How does the provision of shear angle affect the work done in shearing of sheet metal in press work? What is the effect of angles on product quality?(7 marks)

Answer any two question from Q5 (a), (b) or Q5 (c), (d)

5 (a) Explain basic principle of EDM process. Also discuss the characteristics of various materials that are used for EDM tool.(7 marks) 5 (b) Draw neat sketch showing various components of a press working set up and explain importance of each in short.(7 marks) 5 (c) Explain with neat sketch working principle, advantages and limitations of USM.(7 marks) 5 (d) What do you mean by MMR in unconventional machining? How this MMR is affected by various parameters in abrasive jet machining?(7 marks)