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Birla Institute of Technology & Science, Pilani

Work-Integrated Learning Programmes Division


Second Semester 2015-2016

Comprehensive Examination
(EC-3 Regular)

Course No. : ET ZC234


Course Title : MANUFACTURING PROCESSES
Nature of Exam : Open Book
Weightage : 50% No. of Pages =2
Duration : 3 Hours No. of Questions = 4
Date of Exam : 09/04/2016 (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 why the cutting force increases with increasing depth of cut and decreasing
rake angle. [2]
Q.1 (b) Under what conditions would you discourage the use of cutting fluids [2]
Q.1 (c) The accompanying illustration (Fig. 1) shows a part that is to be machined from a
rectangular blank. Suggest the type of operations required and their sequence, and
specify the machine tools that are needed. [2]
Q.1 (d) Explain the possible disadvantages of a machining operation if a discontinuous chip is
produced. [2]
Q.1 (e) What advantages does friction welding have observed are actually due to stress waves
in over the other joining methods? [2]
Q.1 (f) Discuss the factors that influence the strength of (i) a diffusion bonded component and
(ii) a cold welded component. [2]
Q.1 (g) Which materials can be friction stir welded, and which cannot? Explain your answer.
[2]
Q.1 (h) How does the weldability of steel change as the steel’s carbon content increases?
Why? [2]
Q.1 (i) What is the significance of some metals, such as lead and tin, having recrystallization
temperatures at about room temperature? [2]
Q.1 (j) List and briefly explain the three mechanisms by which metals shrink during casting.
[2]

Q.2. Figure 2 shows the final profile to be generated on a MS bar stock of diameter 5.0cm and
4.6 cm length by using a CNC turning center. Write CNC part program using G and M
codes [10]

Q.3. A 150-mm-long, 75-mm-diameter titanium alloy rod is being reduced in diameter to 65


mm by turning on a lathe in one pass. The spindle rotates at 400 rpm and the tool is
traveling at an axial velocity of 200 mm/min Calculate the cutting speed, material removal
rate, time of cut, power required, and the cutting force. [10]

Q.4. Explain the different flushing methods used in EDM [10]

ET ZC234 (EC-3 Regular) Second Semester 2015-2016 Page 1 of 2


ET ZC234 (EC-3 Regular) Second Semester 2015-2016 Page 2

Figure 1

Figure 2

ET ZC234 (EC-3 Regular) Second Semester 2015-2016 Page 2 of 2

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