About this course
A.P.J.Abdul Kalam Technical University (AKTU)
Mechanical Engineering
Manufacturing Process
B.Tech-2nd Year
Sem- 4
Subject Code- KME -403
A topic-by-topic coverage of the entire syllabus in the form of questions and answers.
Comments (0)
Unit-1: Conventional Manufacturing Process
33 Parts
- 2:44 Hr
Que 1.1. What is casting, continuous casting, co2 casting, moulding. What are the basic steps of the metal casting process ?
AKTU
5 Min
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Que 1.2. Describe the die casting and centrifugal casting.
AKTU
5 Min
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Que 1.3. Explain the elements of mould in brief with a neat sketch.
AKTU
5 Min
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Que 1.4. Draw a properly labelled sketch of a cupola and write a brief account of its operation.
AKTU
5 Min
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Que 1.5. Discuss heat transfer during solidification with the help of temperature and distance diagram.
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5 Min
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Que 1.6. Briefly describe solidification of casting.
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5 Min
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Que 1.7. With a solidification factor of 0.97 x 10^6 s/m^2, find the solidification time in seconds for a spherical casting of 200 mm diameter.
AKTU
5 Min
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Que 1.8. What is shrinkage in casting process? Explain its types.
AKTU
5 Min
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Que 1.9. Explain various methods used for designing riser.
AKTU
5 Min
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Que 1.10. What are the common casting defects ? What causes them and what are the measures that can be taken to avoid them ?
Important
5 Min
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Que 1.11. Explain residual stresses in casting process.
AKTU
5 Min
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Que 1.12. Define forging. Also describe the common types of forging operations.
AKTU
5 Min
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Que 1.13. Briefly explain principle and mechanism of rolling process.
AKTU
5 Min
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Que 1.14. What is extrusion ? Explain its types.
AKTU
5 Min
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Que 1.15. What do you mean by sheet metal forming ?
AKTU
5 Min
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Ques 1.16. Discuss briefly about the plastic deformation.
AKTU
5 Min
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Ques 1.17. Define Yield criterion. State Tresca's and Von Mises criteria for plastic deformation. Derive a suitable expression for both criteria.
Important
5 Min
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Que 1.18. What is meant by cold working and hot working? Give the difference between the two.
AKTU
5 Min
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Que 1.19. Derive the expression for load estimation with sliding friction and sticking friction for slab of forging process.
AKTU
5 Min
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Que 1.20. Derive the relation for maximum draft obtained in rolling process.
AKTU
5 Min
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Que 1.21. From first principle, derive the formula for the extrusion of wire with friction where σ refers to the stress in wire at inlet to the die, Db and Da are the inlet and outlet diameters of the wire, B = µ cot α .
-.(µ is coefficient of friction and a is half die angle) and if is the critical shear stress.
5 Min
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Que 1.22. An alloy is hot extruded at 450 °C through square dies without lubrication from 150 mm dia to 50 mm dia. The extrusion speed is 50 mm/s. The flow stress of material at the above temperature is 300 MPa.
AKTU
5 Min
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Que 1.23. Discuss the analysis of wire drawing. Derive an expression for maximum reduction in drawing.
Important
5 Min
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Que 1.24. Calculate the drawing load required to obtain 30 % reduction in area on a 14 mm diameter copper wire. The following data is given α =10°, µ=0.1, σ0=260N/mm^2. Also calculate the power of the electric motor if the drawing speed is 3.0 m/s.
Take motor efficiency as 97 %.
4 Min
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Que 1.25. What is shearing? Describe the various types of shearing operations.
AKTU
5 Min
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Que 1.26. What is deep drawing ? Discuss deep drawing operation in detail. Also list and explain different defects in deep drawing operation.
AKTU
5 Min
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Que 1.27. What is bending in sheet metal working ? Also describe the various types of bending operation.
AKTU
5 Min
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Que 1.28. What is powder metallurgy ? Also write advantages and limitations of powder metallurgy.
AKTU
5 Min
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Que 1.29. Explain the basic steps of powder metallurgy process.
AKTU
5 Min
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VERY IMPORTANT QUESTIONS
Following questions are very important. These questions may be asked in your SESSIONALS as well as UNIVERSITY EXAMINATION
5 Min
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Unit-2: Metal Cutting
35 Parts
- 2:55 Hr
Que 2.1. What do you understand by single point cutting tool ? Briefly explain its various angles.
AKTU
5 Min
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Ques 2.2. What is multi point cutting tool? Also give advantages and disadvantages of it.
AKTU
5 Min
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Que 2.3. Differentiate between orthogonal and oblique cutting.
AKTU 2014-15, Marks 05
5 Min
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Que 2.4. Discuss the various types of chips produced during metal machining with neat sketch.
AKTU 2016-17, Marks 10
5 Min
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Que 2.5. Consider the various forces acting on the chip, draw Merchant force diagram. State the assumptions.
AKTU 2014-15, Marks 10
OR
Explain "Merchant force circle" along with assumptions.
AKTU 2016-17, Marks 10
5 Min
Attachments:
Que 2.6. Draw Merchant's force circle diagram and develop expression for power required in metal cutting and derive Merchant's shear angle relationship.
AKTU 2015-16, Marks 10
OR
Explain Merchant's force circle diagram and derive the merchant's shear angle relationship.
AKTU 2017-18, Marks 10
5 Min
Attachments:
Que 2.7. During an orthogonal cutting the following data is obtained : Rake angle = 15°, chip thickness ratio =0.39, uncut chip thickness, t = 0.6 mm, width of cut, b = 3.3 mm, yield shear stress of material in shear =280 N/mm^2.
-average coefficient of friction on the tool face = 0.7 calculate normal and tangential forces on the tool face.
AKTU 2017-18, Marks 10
5 Min
Attachments:
Que 2.8. The following data relate to orthogonal cutting of mild steel part: Cutting speed =195m/min, tool rake angle =12°,width of cut= 1.75 mm, uncut thickness = 0.25 mm, coefficient of friction between chip and tool = 0.52.
- shear stress of the work material = 385 N/mm2. calculate:
i. Shear angle, and
ii. Cutting and thrust component of machining force.
AKTU 2018-19, Marks 07
5 Min
Attachments:
Que 2.9. What do you understand by tool wear ? Explain its basic types.
AKTU
5 Min
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Que 2.10. How do you define tool life ?What are the factors upon tool life depends ?
AKTU
5 Min
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Que 2.11. Discuss about the surface finish process in metal cutting.
AKTU
5 Min
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Que 2.12. Write short note on surface integrity.
AKTU
5 Min
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Que 2.13. Write a short note on machinability.
Important
5 Min
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Que 2.14. What are the desirable characteristics of cutting tool materials ? Describe them briefly.
AKTU 2014-15, Marks 10
5 Min
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Que 2.15. What are the cutting fluids? Discuss various properties of cutting fluids used during machining.
AKTU 2015-16, Marks 10
5 Min
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Que 2.16. What are the purpose of cutting fluids ? What are their types?
AKTU 2014-15, Marks 10
5 Min
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Ques 2.17. What are the various methods of coating? Explain any two of them.
AKTU
5 Min
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Que 2.18. What do you understand by plain turning, step turning and taper turning ?
AKTU
5 Min
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Que 2.19. Describe twist drill nomenclature using sketches.
AKTU 2014-15, Marks 10
5 Min
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Que 2.20. Explain various drilling operation with neat sketch.
AKTU
5 Min
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Que 2.21. Explain up milling and down milling with a neat sketch.
AKTU
5 Min
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Que 2.22. What is computer numerical control (CNC) system ? Explain.
AKTU
5 Min
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Que 2.23. Explain various elements of a CNC system.
AKTU
5 Min
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Que 2.24. What is additive manufacturing ? Write its advantages and disadvantages.
AKTU
5 Min
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Que 2.25. What is Rapid Prototyping? Write down the advantages, limitations and applications of rapid prototyping.
Important
5 Min
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Que 2.26. Write down the uses of rapid tooling and also discuss its types in short.
AKTU
5 Min
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Que 2.27. Describe physics of welding in detail.
AKTU
5 Min
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Que 2.28. Write down the main design consideration in welding.
AKTU
5 Min
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Que 2.29. Write short note solid and liquid state joining processes.
Important
5 Min
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Ques 2.30. Define joining, fastening.
AKTU
5 Min
Attachments:
VERY IMPORTANT QUESTIONS
Following questions are very important. These questions may be asked in your SESSIONALS as well as UNIVERSITY EXAMINATION.
5 Min
Attachments:
Unit-3: Grinding and Super Finishing
21 Parts
- 1:45 Hr
Que 3.1. Define grinding and grinding wheel.
AKTU
5 Min
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Que 3.2. Write down the factors to be considered in selection of grinding wheel.
AKTU
5 Min
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Que 3.3. Define abrasive. What are its different types ?
AKTU
5 Min
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Que 3.4. Define bond. What are its different types ?
AKTU
5 Min
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Que 3.5. What is the function of bonds in grinding wheel ? Indicate bonding materials and name their corresponding grinding wheel.
AKTU 2014-15, Marks 05
5 Min
Attachments:
Que 3.6. What is meant by grit, grade and structure of grinding wheel ?
AKTU 2014-15, Marks 10
OR
What is meant by grit, grade and structure of grinding wheel ?Explain.
AKTU 2016-17, Marks 09
5 Min
Attachments:
Que 3.7. What do you understand by cutting action of grinding wheel?
AKTU
5 Min
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Que 3.8. Explain grinding wheel specification.
AKTU 2017-18, Marks 10
5 Min
Attachments:
Que 3.9. Describe any four types of bonds for bonded abrasive on a grinding wheel. Explain grinding wheel wear in detail.
AKTU
5 Min
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Que 3.10. Explain three different ways in which the wear of grinding wheel takes place. What can be done to prevent them ?
AKTU
5 Min
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Que 3.11. How are grinding wheels specified ?Clearly differentiate between grade and structure of a grinding wheel ?
AKTU 2015-16, Marks 10
5 Min
Attachments:
Que 3.12. What do you understand by dressing and truing ?
AKTU
5 Min
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Que 3.13. Explain three different ways in which the wear of grinding wheel takes place. What can be done to prevent them ? Differentiate dressing and truing.
AKTU 2015-16, Marks 10
5 Min
Attachments:
Que 3.14. Explain the working mechanism of cylindrical and surface grinding.
AKTU 2016-17, Marks 10
Show that the maximum chip thickness tm in surface grinding, using
grinding wheel diameter D is given by
tm=2vt/ bCVw(√d/D)
Where vt, is the table feed, C is the number of abrasive grains per unit area of the grinding wheel surface, Vw is the grinding wheel surface speed, b is the width and d is the depth of cut.
AKTU 2018-19, Marks 07
5 Min
Attachments:
Que 3.15. Briefly describe the main features of surface grinding.
AKTU 2014-15, Marks 10
5 Min
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Que 3.16. Enlist the typical categories of grinding machines and briefly explain them. What are the cylindrical grinding and centerless grinding ?
AKTU 2017-18, Marks 10
5 Min
Attachments:
Que 3.17. What is super finishing ? Mention its advantages, disadvantages and applications.
AKTU
5 Min
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Que 3.18. Discuss the honing process in detail with neat sketch.
AKTU 2014-15, Marks 05
5 Min
Attachments:
Que 3.19. Explain the lapping process. State its advantages, limitation and uses.
Important
5 Min
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Que 3.20. Write short note on following : a. Polishing, b. Chemical mechanical polishing, and c. Electropolishing.
AKTU
5 Min
Attachments:
VERY IMPORTANT QUESTIONS
Following questions are very important. These questions may be asked in your SESSIONALS as well as UNIVERSITY EXAMINATION.
5 Min
Attachments:
Unit-4: Metal Joining (Welding)
26 Parts
- 2:10 Hr
Que 4.1. What is welding ? Explain the importance of welding.
AKTU
5 Min
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Que 4.2. Classify welding processes.
AKTU
5 Min
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Que 4.3. Briefly describe the gas welding process.
AKTU
5 Min
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Que 4.4. Describe gas cutting process.
AKTU
5 Min
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Que 4.5. Describe the oxy-acetylene welding equipments with neat sketch. Draw the different types of flames used in gas welding. What are the specific uses of each of these flames ?
AKTU
5 Min
Attachments:
Que 4.6. What is arc welding ?Discuss different types of arc in arc welding.
AKTU 2017-18, Marks 10
5 Min
Attachments:
Que 4.7. What arc various types of arc welding power sources ? Give the advantages and limitations of each.
AKTU 2015-16, Marks 10
5 Min
Attachments:
Que 4.8. Explain TIG and MIG welding process and enumerate its advantages.
AKTU 2016-17, Marks 10
5 Min
Attachments:
Que 4.9. Differentiate TIG welding and MIG welding.
AKTU 2014-15, Marks 05
5 Min
Attachments:
Que 4.10. It is required to weld a low carbon steel plate by manual metal arc welding process using a linear VI characteristics DC power source. The following data are available : Open circuit voltage =62 V.
- short circuit current = 130 A, arc length =4 mm, transverse speed of welding = 15 cm/min. Voltage =20 +1.5 L (L is arc length), efficiency of heat input = 0.84, calculate the heat input to the workpiece.
AKTU 2018-19, Marks 07
5 Min
Attachments:
Que 4.11. Briefly describe the main features of resistance welding process with a neat sketch.
AKTU 2014-15, Marks 10
5 Min
Attachments:
Que 4.12. Classify resistance welding. Also write down the advantages, disadvantages and applications of resistance welding.
AKTU
5 Min
Attachments:
Que 4.13. Write a short note on the following types of resistance welding: a. Spot welding, b. Seam welding, and c. Projection welding.
Important
5 Min
Attachments:
Que 4.14. Explain the principle and working of atomic hydrogen welding process. What is resistance welding ? Write its advantages, limitations and applications.
AKTU
5 Min
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Que 4.15. Explain the working of submerged arc welding with the help of suitable diagram, also write down their specific application and advantages and limitations.
AKTU 2018-19, Marks 07
5 Min
Attachments:
Que 4.16. What is electroslag welding ? Also write down the advantages and disadvantages of electroslag welding.
AKTU
5 Min
Attachments:
Que 4.17. What do you understand by friction welding process ? Also give its advantages and disadvantages.
AKTU
5 Min
Attachments:
Que 4.18. Discuss soldering and brazing process.
AKTU 2017-18, Marks 10
5 Min
Attachments:
Que 4.19. Write a note on various brazing methods.
AKTU 2016-17, Marks 06
5 Min
Attachments:
Que 4.20. Write down the advantages, disadvantages and applications of brazing.
AKTU
5 Min
Attachments:
Ques 4.21. Explain various methods of soldering. Also write advantages, disadvantages and applications of soldering.
AKTU
5 Min
Attachments:
Que 4.22. Write short note on adhesive bonding.
AKTU
5 Min
Attachments:
Que 4.23. What is HAZ in welding ? Why weld usually fails in HAZ?
AKTU
5 Min
Attachments:
VERY IMPORTANT QUESTIONS
Following questions are very important. These questions may be asked in your SESSIONALS as well as UNIVERSITY EXAMINATION.
5 Min
Attachments:
Unit-5: Unconventional Machining Processes
27 Parts
- 2:15 Hr
Que 5.1. Explain abrasive machining process. Also classify abrasive machining process. Explain centerless grinding with the help of neat sketch.
AKTU
5 Min
Attachments:
Que 5.2. Explain how the operation of AJM is carried out. What are the limitations of AJM ?
AKTU 2014-15, Marks 10
5 Min
Attachments:
Que 5.3. What is abrasive jet machining (AJM) ? Describe its working with suitable diagram. Also explain the effect of stand-off distance and abrasive grit size on material removal rate in the AJM.
AKTU 2018-19, Marks 07
5 Min
Attachments:
Que 5.4. With neat sketch briefly explain the principle and working of water jet machining (WJM). Also write down its advantages, disadvantages and applications.
AKTU
5 Min
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Que 5.5. Explain the working principle of abrasive water jet machining.
AKTU
5 Min
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Que 5.6. What is ultrasonic machining process (USM) ? Giving suitable sketch, describe its working and also give its advantages, disadvantages and applications.
AKTU
5 Min
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Que 5.7. Write down the process parameters of USM and their effects on MRR.
AKTU
5 Min
Attachments:
Que 5.8. Explain the principle and working of electro discharge machining (EDM) process with suitable sketch. What are the parameters that control the material removal rate in EDM ?
AKTU
5 Min
Attachments:
Que 5.9. Derive the expression for the material removal rate of electro discharge machining.
AKTU
5 Min
Attachments:
Que 5.10. Discuss about the metal removal rate and surface finish obtained in EDM.
AKTU
5 Min
Attachments:
Que 5.11. Discuss the different types of spark generator used in EDM
AKTU
5 Min
Attachments:
Ques 5.12. Explain wire electrical discharge machining (WEDM) with neat sketch.
AKTU
5 Min
Attachments:
Que 5.13. Define dielectric fluid. Write function of dielectric fluid used in EDM.
AKTU
5 Min
Attachments:
Que 5.14. Explain the principle and working of electrochemical machining (ECM). Also give its advantages, disadvantages and applications.
AKTU
5 Min
Attachments:
Que 5.15. Explain the mechanics of metal removal process in ECM. Also discuss the electrochemistry behind ECM process and find the relation for volumetric removal rate.
AKTU 2017-18, Marks 10
5 Min
Attachments:
Que 5.16. Derive the expression for the material removal rate of electro discharge machining. Also differentiate between EDM und ECM process.
AKTU 2018-19, Marks 07
5 Min
Attachments:
Que 5.17. Discuss about the surface finish obtained in ECM process.
AKTU
5 Min
Attachments:
Que 5.18. ECM is performed to remove material from an iron surface of 20 mm x 20 mm under the following condition. Interelectrode gap =0.2mm, supply voltage =12V, specific resistance of electrolyte =2 ohm-cm.
- atomic weight of iron =55.85, valency of iron = 2. Faraday's constant = 96540 coulomb, find the material removal rate in g/sec.
AKTU 2018-19, Marks 07
5 Min
Attachments:
Que 5.19. What does LASER stands for? Explain its working with neat sketch. How metal removal takes place by LBM ?
AKTU 2017-18, Marks 10
5 Min
Attachments:
Que 5.20. Explain laser beam machining process (LBM), giving suitable sketch. Give advantages, disadvantages and its applications.
AKTU
5 Min
Attachments:
Que 5.21. Explain in detail about plasma arc machining (PAM) with suitable sketch.
AKTU
5 Min
Attachments:
Que 5.22. Write advantages, disadvantages and applications of PAM.
AKTU
5 Min
Attachments:
Que 5.23. Explain the principle and working of electron beam machining (EBM). Also give its advantages, disadvantages and applications.
Important
5 Min
Attachments:
Que 5.24. Differentiate between non-conventional and conventional machining. Also give advantages of EBM over USM.
AKTU
5 Min
Attachments:
VERY IMPORTANT QUESTIONS
Following questions are very important. These question may be asked in your SESSIONALS as well as UNIVERSITY EXAMINATION.
5 Min
Attachments:
Short Question:(Unit-1 to Unit-5)
46 Parts
- 3:50 Hr
Q.1. What is casting ? Write the basic steps of casting.
AKTU
5 Min
Attachments:
Q.2. Define moulding. List the various types of moulding process.
AKTU
5 Min
Attachments:
Q.3. What is shearing. Write down the variables which affect the shearing process.
AKTU
5 Min
Attachments:
Q.4. What are the defects in metal forming ?
AKTU
5 Min
Attachments:
Q.5. Differentiate between direct and indirect extrusion.
AKTU
5 Min
Attachments:
Q.6. Define the terms angle of bite and neutral plane in rolling.
AKTU
5 Min
Attachments:
Q.7. What is draft in rolling ?
AKTU
5 Min
Attachments:
Q.8. Defines plastic deformation, recrystallization, bending allowance.
AKTU
5 Min
Attachments:
Q.9. Define powder metallurgy.
AKTU
5 Min
Attachments:
Q.10. Discuss the conditions due to which discontinuous chips produced in metal cutting.
AKTU 2015-16, Marks 02
5 Min
Attachments:
Q.11. Bring out the differences between orthogonal and oblique cutting.
AKTU 2015-16, Marks 02
5 Min
Attachments:
Q.12. What do you understand by continuous chip with BUE ?
AKTU 2017-18, Marks 02
5 Min
Attachments:
Q.13. Discuss the variables affecting tool life.
AKTU 2016-17, Marks 02
5 Min
Attachments:
Q.14. Describe the cutting tool temperature.
AKTU 2015-16, Marks 02
5 Min
Attachments:
Q.15. What are the carbide cutting tool materials and their applications ?
AKTU 2015-16, Marks 02
5 Min
Attachments:
Q.16. What do you understand by boring, reaming and broaching ?
AKTU 2017-18, Marks 02
5 Min
Attachments:
Q.17. What is the difference between end milling and face milling?
AKTU 2017-18, Marks 02
5 Min
Attachments:
Q.18. Differentiate between up milling und down milling.
AKTU 2018-19, Marks 02
5 Min
Attachments:
Q.19. What is CNC and rapid prototyping?
AKTU
5 Min
Attachments:
Q.20. Write down the properties of cutting tool materials.
AKTU 2018-19, Marks 02
5 Min
Attachments:
Q.21. Define the term chip thickness ratio and chip reduction ratio. Also write down the relation between shear angle, chip thickness ratio and rake angle.
AKTU 2018-19, Marks 02
5 Min
Attachments:
Q.22. Name the types of grinding wheel wear.
AKTU 2017-18, Marks 02
5 Min
Attachments:
Q.23. Mention four important factors that influence the selection of grinding wheel.
AKTU 2016-17, Marks 02
5 Min
Attachments:
Q.24. What are different types of bonds used in grinding wheel ?
AKTU 2016-17, Marks 02
5 Min
Attachments:
Q.25. What is an abrasive ? What are its types and characteristics ?
AKTU 2015-16, Marks 02
5 Min
Attachments:
Q.26. Define the term glazing and loading of grinding wheel.
AKTU 2018-19, Marks 02
5 Min
Attachments:
Q.27. What is the main point of difference between dressing and truing ?
AKTU
5 Min
Attachments:
Q.27. What is the importance of truing ?
AKTU
5 Min
Attachments:
Q.29. Defines lapping, centreless grinding, grindability.
AKTU 2016-17, Marks 02
AKTU 2017-18, Marks 02
5 Min
Attachments:
Q.30. What do you mean by welding ? Enlist various defects during welding (name only).
AKTU 2017-18, Marks 02
5 Min
Attachments:
Q.31. What is the principle of gas cutting ?
AKTU
5 Min
Attachments:
Q.32. Write three main differences between TIG and MIG.
AKTU 2017-18, Marks 02
5 Min
Attachments:
Q.33. Differentiate between neutral, oxidizing and carburizing flames.
AKTU 2015-16, Marks 02
5 Min
Attachments:
Q.34. What are the different types of flame used in gas welding ?
AKTU 2018-19, Marks 02
5 Min
Attachments:
Q.35. What is atomic hydrogen welding ?
AKTU
5 Min
Attachments:
Q.36. Mention the applications of friction welding.
AKTU 2016-17, Marks 02
5 Min
Attachments:
Q.37. What is meant by brazing ? How does it differ from soldering?
AKTU 2015-16,Marks 02
5 Min
Attachments:
Q.38. Defines arc blow, HAZ in welding, electroslag welding.
AKTU 2017-18, Marks 02
5 Min
Attachments:
Q.39. What are the controlling parameters of AJM ? State the applications of AJM.
AKTU 2016-17, Marks 02
5 Min
Attachments:
Q.40. Why abrasive is not recycled in AJM ?
AKTU 2018-19, Marks 02
5 Min
Attachments:
Q.41. What are the main components of USM ? What are the purposes of using abrasive slurry in USM ?
AKTU
5 Min
Attachments:
Q.42. Explain the mechanics of material removal in ECM process.
AKTU 2015-16, Marks 02
5 Min
Attachments:
Q.43. What are the purposes of dielectric fluid used in EDM ?
AKTU
5 Min
Attachments:
Q.44. What are the elements of ECM ?
AKTU
5 Min
Attachments:
Q.45. Write down the function of electrolyte.
AKTU 2018-19, Marks 02
5 Min
Attachments:
Q.46. Write down the process parameters of electron beam machining.
AKTU
5 Min
Attachments:
Solved Papers: (2014-15 to 2018-19)
5 Parts
- 0:25 Hr
(SEM. V) ODD SEMESTER THEORY EXAMINATION, 2014-15
Question Paper
5 Min
Attachments:
(SEM. V) ODD SEMESTER THEORY EXAMINATION, 2015-16
Question Paper
5 Min
Attachments:
(SEM. V) ODD SEMESTER THEORY EXAMINATION, 2016-17
Question Paper
5 Min
Attachments:
(SEM.V) ODD SEMESTER THEORY EXAMINATION, 2017-18
Question Paper
5 Min
Attachments:
(SEM.V) ODD SEMESTER THEORY EXAMINATION, 2018-19
Question Paper
5 Min
Attachments:
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