BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI FIRST SEMESTER, 2008-09 Workshop Practice (TA C112) Comprehensive Examination

(Close book) Total Time: 3 hrs. 12 th December, 2008 Max. Marks: 33

NOTE: ANSWER ALL THE QUESTIONS SEQUENTIALLY

PART A Q1(a) Classify following materials into five major classes of materials: (i) Glass (iii) Cement (ii) Nylon (iv) Germanium

[2M]

Q1(b) Identify from the stress-strain curve (Figure I) as to which material is suitable for making (i) spring and (ii) milling Cutter. Give reasons in support of your selection. All figures are drawn for same scale. [2M]

Material B

Material C Stress Material A

Strain

Figure I Figure for question 1(b) Q1(c) Identify which heat treatment process is suitabl e in each of the following case. (i) Making a steel (High carbon steel) suitable for machining by reducing hardness and removing internal stresses. (ii) To refine grain size. (iii)To improve overall hardness of steel. (iv)To improve ductility of highly stressed hardened steel but at the same time retaining sufficient hardness. [2M] Q2(a) What is the purpose of providing porosity in bonded grinding wh eels? [2M] Q2(b) Three grinding wheels P, Q and R of same shape and size with their specifications are given in T able I. It is required to use the grinding wheels for: (i) Grinding of Aluminum and obtain high MRR (ii) Grinding of Cast Iron and obtain low MRR Table I Grinding Wheel Grit size Grade P 10 Z Q 100 E R 500 A Give suitable reasons in support of your answer [3M]

Q2(c) A belt transmits 4KW between two parallel s hafts. The distance between shaft centers is 2m and the diameter of the driver pulley is 800mm. The driver and driven pulley rotate at 100rpm and 200 rpm. Find out the tension induced in tight and slack sides of the belt when pulleys are connected by open belt. Assume coefficient of friction as 0.2. [3M] Q2(d) While machining bronze (having composition say 70% cu and 30% tin) with normal cutting speed, what kind of chips will be produced and why? [2M] Q3(a) Explain the significance of providing rake angle and clearance angle on single point cutting tool. [2M] Q3(b) Classify the operations given below into orthogonal cutting or oblique cutting [2M] (i) Taper turning (ii) Knurling (iii)Turning (iv ) Chamfering Q3(c) Calculate percentage change in cutting speed to give 84% reduction in tool life (Assume n=0.2) [2M] Q4(a) Which plastic is used to produce the following produ cts? (i)Laminated ID card (BITS PILANI) (iii) Spectacles (iii) Adhesives (iv) Pen body [2M]

Q4 (b) Can Injection molding process be carried out without torpedo? Explain . [2M] Q4 (c) Justify the kind of joining process used in the following components? (i) Window grills (ii) Broken leg of a metal chair (iii) Gas tanker (iv) Printed Circuit Board [2M] Q4 (d) (i) Do you think laser beam can be used for joining Aluminum? Justify your answer. [2M] (ii) Can chemical machining be used to manu facture the component shown in Figure II (dimensions in mm) justify your answer. [1M]

Raw material

Component to be manufactured

Figure II for question 4(d) (iii) What are the consequences of excessive / insufficient blending, in case of powder metallurgy process? Explain . [2M]

Workshop Practice (TA C112) SOLUTION KEY: Part A

PART A Q1(a) [0.5M4] Glass..Ceramic Nylon..Polymer Cement...Composite Germanium.Semiconductor [4*0.5M] Q1(b) Ans. Spring : Material B [0.5 M] Reason: Higher resilience [0.5M] (ii) Milling Cutter: Material C [0.5M] Reason: Higher toughness [0.5M] Q1(c). Ans. (i) Annealing [0.5M] (ii) Normalizing [0.5M]] (iii) Hardening [0.5M] (iv) Tempering [0.5M] Q2(a) To provide clearance for chips to escape from grinding wheel [1 M] and to provide cooling [1M] Q2(b) (i) High MRR of soft metal: P[0.5M] + 10 grit size is coarse for high MRR and for soft metal hardest wheel is chosen[1M for explanation ] Low MRR for hard metal: R..[0.5M] + 100 grit size is fine for low MRR cut and for hard metal softest wheel is chosen [1M for explanation ]

(ii)

Q2(c) Ans. Velocity of belt = 4.189 m/sec .[0.5M] D2 = 0.4 m.[0.5M] = 2.942 radians [0.5M] T1-T2 = 954.88 N..[0.5M] T 1/T2 = 1.8[0.5M] T1 = 2.148 KN and T 2= 1.193 KN.[0.5M] Q2(d) Continuous chip are formed as copper % is more in the given composition and copper being ductile Q3(a) Ans. Rake angle is provided for the flow of chips during cutting [1M]and Clearance angle to prevent friction between tool and machining face of

the work piece. Q3(b) Knurling, is orthogonal Taper turning, Chamfering and turning are oblique

[1M]

05M4

Q3(c) Calculate percentage change in cutting speed to give 84% reduction in tool life (Assume n=0.2) [2M] 0.2 Ans. (V 2/V 1) = (T1/T2) = (T1/0.16T2)0.2 = 60.2 = 1.424 therefore 42.4% increase in cutting speed Q4(a) adhesives: thermosetting plastics, rest all thermoplastics ? [0.5M4] Q4 (b)Ans. No. As Torpedo causes the molding material to come more thoroughly into contact wi th the walls of the heating chamber, thus when the material reaches the nozzle it should be sufficiently fluid. [2M] Q4 (c) Ans. widow grills: gas welding Broken leg of chair: gas welding Gas tanker: rivets PCB: soldering

[0.5M4]

Q4 (d) NO . Al being a reflective material reflects the laser beam that is incident on the surface of the work piece [1M]

Ans. NO ,The chemical (enchant) being a liquid spreads sideways, hence CM cant be used for larger depths. [1M] (iii). Excessive mixing work hardens (strain hardening) the metallic powders making the compaction difficult If mixing is not proper, the ingredients will not be distributed uniformly and the desired properties will not be obtained in the material [2M]