Roll Number: Thapar Univer sity Patiala Department Mechanica.l of Engineering .

Mechanical 3'" Year, I E-MBA 3'o Year ME002: Manufacruring Technology Fall Semester,Mid semesterexam, 22 September,2010 Time: 02 Hours; Maximum marks: 60 Name of Faculty: Dr Rahul Chhibber, Mr, Ankur GoeI

NOTE:All questions are compulsory, Attempt all parts of the attemptedquestions. Missing data if any may suitably be assumed. Support your answers with neat sketches wherever rcquired
I (a) Amongthe typesof sands usedin mouldingsandpreparation which sandhasthe highestmeltingpoint 2 marks andwhich hasthe lowestcoefficientofthermal exnansion? out around1600centipFades whichtvpe ofclay is used? I mark Jb)_ Whencastingis carrield at temperatures Whatis the idealshape riserandwhy? ola 2 marks (d) ln the cupola furnace what are the various zones and in which zone do we find the maximum 3 mark temperatures? fe) is !!ich type of die castingprocess usedto cast copperbasealloysandwhy? 2 marks (0 Which type of Manual Metal Arc Welding eleotrodes also known as generalpurposeelectrodes I mark are ald canbe usedeffectivelyfor bothAC andDC polarities? (e) What is the coating factof in Manual Metal Arc welding electrodes? are electrodesclassified 2 marks How acaording mngeof coatingfactor? to (h) Why thori4ledtungsten electrodgs preferred are over puretungsten electrodes TIG weldins? in I marks (i) When and Why does mode of metal transfer changefrom globular to axial spray mode, for same diameterelectrode. Whatarethe othermodesof metalTransfr? matks Why do we prefer using constantcurrenttype of welding power sourcewhon welding is doneusing I mark Shielded metalarcweldingprocess. (k) Differentiatebetween orthogonal co-ordinate and reference systems usedin tool nomenclature 1 mark (D Differentiatebetween orthogonal obliquecuttingprocess and I mark (m) Enlist the seven basicelements singlepoint cuttingtool nomenclaturc of 2 marks (n) Definetool life? What arethe factorsaffectinstool life? 2 mark (o) How do cutting fluids affect tool life? I mark 2 marks ll/hef is sintering?Why is it requiredto sinterthe powdermetallurgycompact? (q) What is atomization ? What are other methods of powder preparation? 2 mark (r) What is the thicknessrqngeof the shell in shell moulding process? I mark (s) Differentiatebetween Misrun andCold Shut. I mark Whatis friability?Whatis grinding ratio(G-Ratio) ? 2 mark 2(a) The following^equatiol_for life is givenfor a tuming operation tool 4 marks

c)

A 60 minute tool life wasobtained whilecuttingat V= 30 m/mi4 f = 0.3mm/rev. d = 2.5mm and Determinethe changein tool life if the cutting speed,feed and depthof aut are increased by 20% indirriduallyandalsotakentogether. (b)
An aro weld is being made on a steel plate under the fo[owing conditions, Welding Voltage 20 V, 2 marks welding current 200 A, Heat h'ansfer efticiency f1 = 90%, melting efficiency f2= 30%, welding speed = 5 mm/s, The melting point of steel plate is 800 degree centigrades. Calculate the total weld metal cross-section areamelted.

(c)

of ks uptoofthe constituents 1000 andis made composition variousolements of Constituent Proportion Percentage %
o/oc o/oSi o/oMn
o/oP

l )_ | marks
%S

3(a)

(b) (c) (o,

I i

0.4 0.02 J.) 3 20 Pieiron I u.) 0.8 0.01 1.5 20 Pis Lon 2 0.5 0.08 J.) 1.8 0"60 Scrap 30 0.035 0,6s 0.16 3.3 2.5 Retums 30 Phosphorus, Sulfurin the melt assuming a Manganese, of Silicon, Calculate percentage Carbon, the 'a for a a net gainof O.l|y:o Carbon, net lossof 15Yo silicon, net lossof 10%for manganese, ne1 for lossof ohosphorus 60/o, netgainof sulfurof 0.01%, of a grinding wheelof diameter mm,having 4 marks 150 resinoid surface Mr. Odumbe usinga siliconcarbidois of 9 cutting pointsper mm' of its surfaceareaat a surfacespeed 1600m/secfor removinga layer of with a speed of400 m/ sec. workpiece whichis beingmoved 4 metal mm &oma roundbaraluminum chip thicknoss ratio being 16. in The layer is removed form of chipswith chip width to average and it for chip by the Kindly helpMr. Odumbe deriving expression undeformed thickness estimating for this grindins operation. ofdifferentshapes sucl 3 marks times"t"for casting the UsingChvorinov's equationcompare solidification , '. F'ind theirr*iio. havi.ig same volume"V ascuiric. cylindrical spherical, and for Derivethe expression critical radiusofNucleation "r", in termsof surfacefiee energro, volume 2 marks Nucleation. ofhomogeneous freeenergychange for case AF, of CardModel, derivethe expression shearangle"q" in termsof backrake angle 2+4 UsingPispanen's '1" for orthogonal machiningusing singlepoint cutting tool. Also for the same marks "a"and cutting ratio Force(F"), FrictionForce(F), of casederivethe expression ShearForce(F"), Normal to Shear (F6) andVertical Thrustforce (Fv) l.trormal friction lc.c: (\D in iermsof HorizontalCuttingForce to angle(rp)andbackrakeangle(4.)usingMerchantCycle on the singlepoint e';.iing torrl andtle shear

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