Advanced Manufacturing - Manufacturing Processes II - Production & Industrial Engineering Previous Year Questions

1

2007 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2007

Which one of the following process conditions leads to higher MRR in ECM process?

A

higher current, larger atomic weight

B

higher valency, lower current

C

lower atomic weight, lower valency

D

higher valency, lower atomic weight

Open complete paper

2

2007 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2007

In an Abrasive Jet Machining process, if \( Q \) = flow rate of the abrasives and \( d \) = the mean diameter of the abrasive grain, then material removal rate is proportional to

A

\(Q d^2 \)

B

\(Q d \)

C

\(Q d^2 \)

D

\(Q d^3 \)

Open complete paper

3

2008 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2008

In an electro chemical machining (ECM) operation, a square hole of dimensions 5 mm × 5 mm is drilled in a block of copper. The current used is 5000 A. Atomic weight of copper is 63 and valency of dissolution is 1. Faraday’s constant is 96500 Coulomb. The material removal rate (in g/s) is

A

0.326

B

3.260

C

3.15 × 10³

D

3.15 × 10⁵

Open complete paper

4

2009 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2009

A titanium sheet of 5.0 mm thickness is cut by wire-cut EDM process using a wire of 1.0 mm diameter. A uniform spark gap of 0.5 mm on both sides of the wire is maintained during cutting operation. If the feed rate of the wire into the sheet is 20 mm/min, the material removal rate (in mm²/min) will be

A

150

B

200

C

300

D

400

Open complete paper

5

2010 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2010

Ultrasonic machines, used in material removal processes, require ultrasonic transducers. The transducers work on different working principles. One of the working principles of such ultrasonic transducers is based on

A

eddy current effect

B

Seebeck effect

C

piezo-resistive effect

D

piezo-electric effect

Open complete paper

6

2010 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2010

Keeping all other parameters unchanged, the tool wear in electrical discharge machining (EDM) would be less if the tool material has

A

high thermal conductivity and high specific heat

B

high thermal conductivity and low specific heat

C

low thermal conductivity and low specific heat

D

low thermal conductivity and high specific heat

Open complete paper

7

2011 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2011

Which of the following welding processes results in the smallest heat affected zone?

A

Shielded metal arc welding

B

Gas welding

C

Laser beam welding

D

Thermit welding

Open complete paper

8

2011 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2011

While removing material from iron (atomic weight = 56, valency = 2 and density = 7.8 g/cc) by electrochemical machining, a metal removal rate of 2 cc/min is desired. The current (in A) required for achieving this material removal rate is

A

896.07

B

14.93

C

448.03

D

53764.29

Open complete paper

9

2012 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2012

In abrasive jet machining, as the distance between the nozzle tip and the work surface increases, the material removal rate

A

increases continuously.

B

decreases continuously.

C

decreases, becomes stable and then increases.

D

increases, becomes stable and then decreases.

Open complete paper

10

2013 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2013 [Session 1]

During the electrochemical machining (ECM) of iron (atomic weight = 56, valency = 2) at current of 1000 A with 90% current efficiency, the material removal rate was observed to be 0.26 gm/s. If Titanium (atomic weight = 48, valency = 3) is machined by the ECM process at the current of 2000 A with 90% current efficiency, the expected material removal rate in gm/s will be

A

0.11

B

0.23

C

0.30

D

0.52

Open complete paper

11

2013 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2013 [Session 1]

In water jet machining, the water jet is issued through a 0.3 mm diameter orifice at a pressure of 400 MPa. The density of water is 1000 kg/m³. The coefficient of discharge is 1.0. Neglecting all losses during water jet formation through the orifice, the power of the water jet in kW is

A

25.3

B

50.6

C

75.9

D

101.2

Open complete paper

12

2013 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2013 [Session 4]

In water jet machining, the water jet is issued through a 0.3 mm diameter orifice at a pressure of 400 MPa. The density of water is 1000 \( kg/m^3 \). The coefficient of discharge is 1.0. Neglecting all losses during water jet formation through the orifice, the power of the water jet in kW is

A

25.3

B

50.6

C

75.9

D

101.2

Open complete paper

13

2014 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2014

Find the correct combination of manufacturing processes to produce the part, shown in figure, from a blank (holes shown are with square and circular cross-sections).

A

Drilling and milling on column and knee type universal milling machine

B

Die-sinking and CNC Wire-cut EDM process

C

Die-sinking and CNC drilling

D

CNC Wire-cut EDM process only

Open complete paper

14

2014 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2014

A hard ceramic marble, having density (ρ) of 3000 kg/m³ and diameter (d) of 0.025 m, is dropped accidentally from a static weather balloon at a height of 1 km above the roof of a greenhouse. The flow stress of roof material (σ) is 2.5 GPa. The marble hits and creates an indentation on the roof. Assume that the principle of creation of indentation is the same as that in case of abrasive jet machining (AJM). The acceleration due to gravity (g) is 10 m/s². If V is the velocity, in m/s, of the marble at the time it hits the greenhouse, the indentation depth (δ = 1000 × √(ρ/6σ) × d × V), in mm, is ______

Check answer

Open complete paper

15

2016 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2016

Consider the following statements.
(P) Electrolyte is used in Electro-chemical machining.
(Q) Electrolyte is used in Electrical discharge machining.
(R) Abrasive-slurry is used in Ultrasonic machining.
(S) Abrasive-slurry is used in Abrasive jet machining.
Among the above statements, the correct ones are

A

P and R only

B

Q and S only

C

Q, R and S only

D

P and Q only

Open complete paper

16

2016 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2016

In abrasive water jet machining, the velocity of water at the exit of the orifice, before mixing with abrasives, is 800 m/s. The mass flow rate of water is 3.4 kg/min. The abrasives are added to the water jet at a rate of 0.6 kg/min with negligible velocity. Assume that at the end of the focusing tube, abrasive particles and water come out with equal velocity. Consider that there is no air in the abrasive water jet. Assuming conservation of momentum, the velocity (in m/s) of the abrasive water jet at the end of the focusing tube is ________.

Check answer

Open complete paper

17

2017 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2017

In chemical machining, the etch factor is expressed as

A

\(\frac{undercut}{depth\ of\ cut}\)

B

\(\frac{depth\ of\ cut}{undercut}\)

C

\(\frac{workpiece\ wear}{tool\ wear}\)

D

\(\frac{tool\ wear}{workpiece\ wear}\)

Open complete paper

18

2017 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2017

A surface of 30 mm × 30 mm of an iron block is machined using electrochemical machining process. The atomic weight and valency of iron is 55.85 and 2, respectively. The density of iron is 7,860 kg/m³. If input current is 1,000 A and Faraday’s constant is 96,540 Coulombs, then the feed rate (in mm/min) is __________ (up to two decimal places).

Check answer

Open complete paper

19

2017 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2017

An electron beam welding process uses 15 mA beam current at an accelerating voltage of 150 kV. The energy released per second by the beam (in J) is ______________(up to one decimal place).
(1 Ampere = 6.28 × 10¹⁸ electrons per second, 1 eV = 1.6 × 10^-19 J)

Check answer

Open complete paper

20

2018 · Production & Industrial Engineering · Manufacturing Processes II · Advanced Manufacturing

Production & Industrial Engineering (PI) 2018

To make holes of 0.5 mm diameter and 30 mm depth in a mild steel component, the most suitable process is

A

chemical machining

B

electrochemical machining

C

abrasive jet machining

D

plasma arc machining

Open complete paper