iind year.doc

1

Assignment Booklet

BTME Programme

Second SemesterBME 008 Machining Technology

BME 009 Computer Programming and Application

BME 010 Tool Engineering and Management

BME 011 Computer Aided Process Planning

BME 012 Manufacturing System, Integration and Control

BME 013 Production Management

BME 014 Metrology and Instrumentationh

SCHOOL OF ENGINEERING & TECHNOLOGYINDIRA GANDHI NATIONAL OPEN UNIVERSITY

Maidan Garhi, New Delhi – 110 068

JULY 2011

Q.1 (a) Derive the following relation for the shear angle () :

where r = Chip thickness ratio, and

= Tool rake angle.

(b) What do you understand by M-series and T-series of HSS? Describe the significant characteritics of high speed steels (HSS).

Q.2 (a) With the help of neat sketch describe centreless grinding. Give its application, advantages and disadvantages.

(b) List various advanced finishing processes. Breifly describe lapping and burnishing operation with their applications.

Q.3 Write short notes on the following :

(i) Ion Beam Machining,

(ii) Plasma Arc Machining, and

(iii) Comparison of unconventional machining processes in terms of process, MRR and application.

Q.4 (a) With the help of Merchant’s model determine the cutting force while machining an alloy steel plate in conditon of orthogonal cutting. The tool has a rake angle of 10º, uncut chip thickness is 1 mm and width of the cut is 5 mm.

The yield strength of the alloy in shear = 240 N/mm2.

(b) Describe atleast five additives for coolants and give their functions.

Q.5 (a) Explain following kinds of tool damage :

(i) Flank wear,

(ii) Crater wear, and

(iii) Chopping.

(b) Mention the various types of bonds used in the making of grinding wheels. Also mention their applications.

(c) Describe the marking system in the grinding wheels.2

TUTOR MARKED ASSIGNMENTBME-008

MACHINING TECHNOLOGY

Note : All questions are compulsory and carry equal marks. This assignment is based on all Blocks of Machining Technology.

.

Maximum Marks : 100Weightage : 30%

Course Code : BME-008 Last Date of Submission : Nov. 30, 2011

BTME

Q.6 (a) Explain the principle of Electro-chemical machining. Using suitable notations establish the relationship for the electrode feed rate theoretically in a ECM.

(b) With a neat sketch desribe the electrolytic grindig process. Give its advantage and applications.

Q.7 (a) Describe the process capabilities of Electron Beam Machining. Compare it with LBM.

(b) Discuss the effects of the following parameters on working accuracy and metal removal rate in AJM :

(i) Grain size,

(ii) Jet velocity, and

(iii) Stand off distance.

Q.8 (a) Name different types of chips formed in metal machining. Which type of chip is suitable to enhance tool life? Give the function of chip breaker.

(b) Write the assumption made by merchant based on thin zone model.

(c) Show that in case of ideal orthogonal cutting operation the shear strain undergone by the chip during it’s removal from the workpiece would be minimum if the chip thickness ratio is ‘1’.

Q.9 (a) With the help of schematic diagram describe the mechanics of metal removal in Honing operations. Also explain process capabilities and applications of honing.

(b) With the help of suitble sketches explain the working of ultrasonic machining process. Also cite it’s applications alongside justification of the same.

Q.10 (a) With the help of neat sketch explain the mechanics of metal removal in EDM.

(b) Sketch the effects of following parameters on MRR during EDM using RC-circuit.

(i) Resistance,

(ii) Capacitance, and

(iii) Current Density.

3

Q.1 (a) (i) The approximations to the number 2/3 are given as 0.6, 0.66, and 0.67. Which of these is the best approximation and why?

(ii) Find how many significant digits is the value 355/113, an accurate approximation to

(b) If are accurate to six significant digits, then find the number of significant digit in z = x – y.

(c) Prove the following relations :

Q.2 (a) Solve the following equations by Gauss-Seidal iteration method :

20x + y – 2z = 17

3x + 20y – z = 18

2x – 3y + 20z = 25

(b) Find the Lagrange interpolating polynomial from the given following data :

x – 2 1 0 2

f (x) 3 – 3 1 – 1

Also compute the approximate value of f (1.5).

(c) Compute the cube root of 24 by using Newton-Raphson method.

Q.3 (a) Solve the following equation by Jacobi’s method :

5x + 2y + z = 12

x + 4y +2z = 15

x +2y + 5z = 20

(b) Find the real root of the equation 3x = cos x + 1 by Newton-Raphson method.

Q.4 (a) Using Newton’s interpolation formula, find the value of f (1.6) if4


COMPUTER PROGRAMMING AND APPLICAION

Note : All questions are compulsory and carry equal marks. This assignment is based on all Blocks of Computer Programming and Application.

.



BTME

x 1 1.4 1.8 2.2

f (x) 3.49 4.82 5.96 6.5

(b) Solve the following equations by Gauss Elimination method:

Q.5 (a) If and error in x, y, z is 0.001, compute the relative maximum error in p when

x = y = z = 1.

(b) Find a real root of the equation by the Regula-Falsi method correct to three decimal places.

Q.6 (a) Using Runge-Kutta method of order four, find y (0.2) given that ; y (0) = 1,

taking h = 0.1.

(b) A root of the equation xex – 1 = 0 lies in the interval (0.5, 1.0). Determine this root correct to three decimal places using regula-falsi method.

(c) Evaluate . Using the Simpson’s rule with .

Q.7 (a) Find a real root of the equation . Using the bisection method correct to three decimal places.

(b) Using Newton-Raphson method obtain a root of the equation correct to three decimal places. Assume .

(c) For the data :

x 0 0.2 0.4 0.6 0.8 1.0

f (x) 7.0 6.008 5.064 4.216 3.512 3.0

Find an approximation to f (0.1) and f (0.3) by using Newton’s Forward difference formula.

Q.8 (a) Write a C++ programme to calculate the values of the function for

x = 10 to 10, x should take values 10, 8, 6, . . . 6, 8, 10.

(b) (i) What will be the output produced by following code :

for (i = 10; i< = 50; I + = 10)

{

j = i / 2

cout <<j<< ” ” ;

}

(ii) What will be the output produced by following code fragment?

for (i = 10; i< = 50; I + = 8)

j = i / 2

cout <<j<< ” ” ;

5

Q.9 (a) Write a C++ programme that gives the option of converting Fahrenheit to Celsius or Celcius to Fahrenheit.

(b) Write a C++ programme to calculate area of a circle, a rectangle or a triangle depending upon a user’s choice.

Q.10 (a) Given three numbers A, B, and C, write a C++ program to write their values in descending order.

(b) Write a C++ program to :

(i) Find the radius of a circle whose area is given

(ii) Calculate the volume and surface area of a sphere.

6

Q.1 Differentiate between the following :

(i) Facing and Turning

(ii) Drilling and Trippanning

(iii) Broaching and Milling

(iv) Blanking and Punching

(v) Notching and Shaving

(2 5 = 10)

Q.2 Describe the important characteristics and its applications of following tool materials :

(i) High Carbon Steel

(ii) High Speed Steel

(iii) Stellite

(iv) Carbide

(v) Ceramics

(2 5 = 10)

Q.3 (a) State clamping principle. Describe the various types of clamps with its suitable application.

(b) Explain with neat sketches the principle of indexing jig.

(5 + 5 = 10)

Q.4 List various types of fixtures. Also explain any three types of fixtures with its industrial applications.

(10)

Q.5 (a) What are various types of blanking and piercing dies? Explain in detail.

(b) Briefly discuss various types of forming tools with neat sketch.

(5 + 5 = 10)

Q.6 (a) What are the various types of hand tools used in foundry? Explain its detail.

(b) Explain important types of mechanical tools used in foundary.

(5 + 5 = 10)

7


TOOL ENGINEERING AND MANAGEMENT

Note : All questions are compulsory and carry equal marks. This assignment is based on all Blocks of Tool Engineering and Management.


Course Code : BME-010Last Date of Submission : Nov. 30, 2011

BTME

TUTOR MARKED ASSIGNMENTBME 011

COMPUTER AIDED PROCESS PLANNING

Note : All questions are compulsory and carry equal marks. This assignment is based on all Blocks of Computer Aided Process Planning.


Course Code : BME 011 Last Date of Submission: 30th Nov. 2011

BTME

Q.7 (a) What is the purpose of laying out the workpiece? Explain prick and centre punch in detail.

(b) Explain laying out center hole. Discuss various steps involved in laying out centre hole using centre head.

(5 + 5 = 10)

Q.8 (a) Describe the process of laying out internal and external radius.

(b) What are the causes of accidents? Describe the various safety norms in the industry.

(5 + 5 = 10)

Q.9 (a) What are the principle parameters in designing sideways? Design the sideways for machine tool.

(b) Explain the design criteria for selection of materials for machine tool structure.

(5 + 5 = 10)

Q.10 (a) What is process planning? Explain the significance of setup planning in process planning.

(b) Explain in brief, the working of web-based virtual machine tool operations (WVMT).

(5 + 5 = 10)

8

Q.1 (a) Explain the processing sequence required to fabricate a single part on multiple machines.(b) What are the most economic considerations the process planner must take, while

preparing a process plan?(5 + 5 = 10)

Q.2 (a) Differentiate between ‘bottom-up’ and ‘top-down’ approach for a CAPP implementation.(b) Discuss the four important modules and their functions in a typical CAPP system.

(5 + 5 = 10)Q.3 (a) List atleast eight criteria for selection of a CAPP system in a forming process.

(b) A cast workpiece is finished by machining. Discuss how would you select the workpiece area to locate, support and hold the workpiece during machining process.

(5 + 5 = 10)Q.4 (a) Make a block diagram of material requirement planning system. Describe the role of

computer in production planning with the help of above diagram.(b) Briefly discuss the various approaches available for computer aided process planning.

(5 + 5 = 10)Q.5 (a) Describe the generative system of CAPP. How expert system or knowledge based

system is used to enhance the capability of this system?(b) A forming tool machining at 40 m/minute requires re-sharpening after 40 minutes. What

should be the cutting speed for prolonging tool life to 80 minutes? Assume n = 0.15.(5 + 5 = 10)

Q.6 (a) Estimate the actual machining time required for the component of diameter 48 mm and length 150 mm. The available speeds are 70, 110, 176, 280, 440, 700, 1100, 1760 and 2800 units. Use a roughing speed of 32 m/min and finish speed of 65 m/min. The feed roughing is 0.25 mm/rev., while that for finishing is 0.12 mm/rev. The maximum depth of cut for roughing is 2 mm. Finish allowance may be taken, as 0.75 mm. Blank to be used for machining is 60 mm in diameter.

(10)Q.7 (a) How does the cutting conditions influence the selection of a tool? Explain briefly.

(b) A carbide cutting too has tool life exponent n = 0.27. It gives a tool life of 60 minutes while machining a mild steel workpiece at a cutting speed of 120 m/min. Compute the tool life if it is to be cut at a 20% higher cutting speed. Also what is the cutting speed if the tool life is to be doubled?

(5 + 5 = 10)

Q.8 (a) A 20 mm 150 mm diameter HSS side and face milling cutting is to be used to cut a groove into a piece of brass with one cut. The groove is 20 mm wide, 4 mm deep and 250 mm long. Calculate the total machining time. Justify the assumptions made if any.

(b) The average of averages of a number of samples of samples of size 9 was determined to be 125. The average range was 17.82 and the standard deviation was 6. The following measurements were taken in a sample : 120, 132, 124, 130, 118, 132, 135, 121, and 127. Is the process in control?

(5 + 5 = 10)

Q.9 (a) Create the part families for the following matrix using King’s algorithm.

Part

MachineP1 P2 P3 P4 P5 P6 P7 P8

m1 1 1 1

m2 1 1

9

m3 1 1

m4 1 1

m5 1 1

m5 1 1 1 1

(b) With the help of a flow chart, explain the functions carried out by various modules in a sheet metal CAPP system.

(5 + 5 = 10)

Q.10 (a) Distinguish clearly between drop forging and press forging processes with reference to the process and products obtained.

(b) Explain how a tube can be manufactured from sheet by a suitable welding process.

(5 + 5 = 10)

10


MANUFACTURING SYSTEMS INTEGRATION AND CONTROL

Note : All questions are compulsory and carry equal marks. This assignment is based on all Blocks of Manufacturing Systems Integration and Control

.



BTME

Q.1 What is automation? What are the three basic elements of automation? Explain the role of automation in manufacturing.

(10)

Q.2 What do you understand about Quality Function Deployment (QFD)? Where actually the concept of QFD is used in manufacturing systems? Explain with suitable examples.

(10)

Q.3 (a) Discuss about CIM database and multi-objectives decision support system.

(b) Why data integration is necessary for an integrated manufacturing enterprise?

(5 + 5 = 10)

Q.4 What do you understand about agile manufacturing system? Explain the changes required in present day manufacturing system to adopt agile manufacturing system.

(10)

Q.5 Write short notes on the following :

(i) Virtual manufacturing system

(ii) Virtual enterprise

(iii) Virtual environment

(iv) Virtual prototyping

(2.5 4 = 10)

Q.6 (a) Discuss about the unique characteristics of computer controlling scheduling.

(b) Discuss about the main objectives of short-term scheduling and control.

(5 + 5 = 10)

Q.7 Describe in detail about the decision tree based production control system (PCS) with a suitable case example.

(10)

Q.8 Define supply chain management. How it is different from logistics? Describe the managerial and behavioural components of a supply chain?

(10)

Q.9 Explain in detail with suitable examples of the following concepts :

(i) Enterprise Resource Planning (ERP)

(ii) Web or e-enable Supplychain.

(10)

Q.9 What do you understand by statistical quality control? Describe different types of control charts used in manufacturing systems with suitable problems and solutions.

(10)

11

12


PRODUCTION MANAGEMENT

Note : All questions are compulsory and carry equal marks. This assignment is based on all Blocks of Production Management

.



BTME

Q.1 (a) List five major reasons why a new electronic components manufacturing firm should move into your city or town.

(b) How do facility location decisions differ for service facilities and for manufacturing plants?

Q.2 (a) How does the production volume affect break-even analysis?

(b) Clean-clothes cleaners is in a dry cleaning business that is considering four possible sites for its new operation. The annual fixed and variable costs for each site have been estimated as follows :

Location Fixed Cost Variable Cost

A Rs. 350,000 Rs. 5/unit

B Rs. 170,000 Rs. 25/unit

C Rs. 100,000 Rs. 40/unit

D Rs. 250,000 Rs. 20/unit

(i) Plot the total cost curves for each location on the same graph and identify the range of output for each location provides the lowest total cost.

(ii) If demand is expected to be 10,000 units per year, which is the best location?

Q.3 (a) Historical demand for a product is

Demand

January 12

February 11

March 15

April 12

May 16

June 15

(i) Using weighted moving average with weights of 0.60, 0.30 and 0.10, find the July forecast.

(ii) Using a simple three month moving average, find the July forecast.

(iii) Using single exponential smoothing with = 0and a June forecast = 13, find the July forecast.

(b) You need to test the validity of forecasting model. Here are the forecasts for a model you have been using and the actual demand that occurs :

Week Forecast Actual

1 800 900

2 850 1000

3 950 1050

4 950 900

5 1000 900

6 975 1100

Compute the MAD and tracking signal.

Q.4 (a) Describe supplier relation both before and after implementation of a JIT system.

(b) What are the objectives of MRP? Explain how each of these objectives is achieved.

13

Q.5 A building project consists 10 activities, A, B, C, etc. as listed in the following table. Normal duration of each activity along with, preceding and succeeding activities are also given :

Activity Preceding Activity

Succeeding Activity

Estimated Duration (Days)

A B, C 5

B A D, E 2

C A F, G 6

D B H 4

E B I 4

F C I 2

G C J 3

H D 8

I E, F 7

J G 7

Draw the network and determine the critical path and total project duration.

Q.6 (a) Define the term ‘method study’ and state its objectives.

(b) Distinguish between time study and motion study with suitable examples.

Q.7 Write the salient features of Enterprise Resource Planning (ERP). Discuss the factors in successful implementation of ERP in a manufacturing company.

Q.8 (a) What do you understand by ‘logistics’? Discuss the logistics elements for a typical manufacturing company.

(b) Discuss basic principles of SCM that are applicable in any one of the following sectors :

(i) Health care,

(ii) Education, and

(iii) Retail.

Q.9 Write short notes on following :

(i) Theory of Constraints, and

(ii) Capacity Planning.

Q.10 (a) Distinguish between single machine scheduling and flow shop scheduling.

(b) Consider the following 2 machines and 6 jobs flow shop problem :

Job Machine 1 Machine 2

1 5 7

2 10 8

3 8 13

4 9 7

5 6 11

6 12 10

Obtain the optimal schedule and corresponding make span for the above problem.

14

TUTOR MARKED ASSIGNMENTBME 014

METROLOGY AND INSTRUMENTATION

Note : All questions are compulsory and carry equal marks. This assignment is based on all Blocks of Computer Aided Process Planning.


Course Code : BME 014 Last Date of Submission: 30th November, 2011

BTME

Q.1 State second law of motion and derive unit of force in 51 and FPS units.A block weighing 40 kgf is pushed on a rough plane over a distance of 2 m. The coefficient of friction between block and the rough plane is 0.3. Find the power used in pushing the block if the time taken in displacement is 15 s.

Q.2 Define :(i) Arithmetic mean

(ii) Geometrical mean(iii) Median

(iv) Deviation(v) Standard deviation.

Show that arithmetic mean minimizes the sum of the squares of deviation from mean value.Q.3 The diameter of a bar is measured as (10 0.2) mm. It is subjected to an axial load of

(5 2%) kN. Calculate percentage error in stress .

Q.4 During a tension loading of a cylindrical specimen of steel load (P) and elongation ( l) were recorded. The diameter of specimen was 15 mm and gauge length was 75 mm. Establish relation between P and l and calculate modulus of elasticity of steel. Assume P and l are linearly related.

P or yi (N) l or xi (mm)9000 0.0180

15000 0.031020000 0.041725000 0.052130000 0.062735000 0.0730

Q.5 (a) Define by illustration : Clearance, transition and interference fits.(b) Distinguish between unilateral and bilateral tolerances.(c) A gear has to be mounted on a shaft whose nominal diameter is 120 mm. An

interference fit H7/u6 is desirable. Calculate the minimum and maximum diameter of the shaft and interference.Hole tolerance H7 means – 0.00, + 8.035.Shaft tolerance u6 means + 0.144, + 0.144 + 0.022.

Q.6 A few gauges are listed below. Collect them is common class and name the class.

16

(i) Taper gauge(ii) Gauge for checking taper

(iii) Thread gauge(iv) “go” and “not go” gauge

(v) Master gauge(vi) Plug gauge

(vii) Working gauge(viii) Indicating gauge

(a) Describe feller gauge and snap gauge.(b) Describe the use of following gauges

(i) Template gauge(ii) Indicating gauge

(iii) GO and NOT Go gaugeQ.7 (a) Describe function of calipers. Describe one each of outside and inside calipers.

(b) What is vernier scale? Is it read in micrometer?(c) What are the functions of (i) thread micrometer caliper, (ii) V-anvil micrometer caliper

and (iii) blade type micrometer.

Q.8 (a) If the resistance of wire is given by where = resistivity, l = length of wire,

A = area of cross-section, and wire is pulled so that strain is induced in wire, show that

where is Poisson’s ratio. Define gauge factor of wire (strain sensitivity).

(b) Define a comparator and compare mechanical comparator with electrical comparator.(c) An electric wire of gauge length 20 mm is pulled to extend by 10– 3 mm. If the gauge

factor is 2.2 and = 0.3, find % change in resistivity.Q.9 (a) What is the difference between a microscope and projector and where is latter

preferred? Which lens of projector has to be heat resistant? What function does this lens perform? Are there any other lenses used in projector? Show a sketch with lens positions.

(c) It is said that a tool maker’s microscope can measure various characteristics of engineering components. Select those which cannot be measured by this instrument.(i) Surface roughness, (ii) distance between holes, (iii) module of gear, (iv) angle in thread, (v) core and major diameter of thread, (vi) % carbon in steel and (vii) minimum diameter of a specimen.

Describe procedure of measuring any two characteristics from above list.Q.10 (a) What functions are performed by CMM? Describe probes which are used in CMM.

(b) Describe in brief how a CMM can result in :(i) reduced operator influence,

(ii) reduced time to setup the job on table,(iii) flexibility in measuring dimensions and shapes, and

(iv) improved productivity.(c) What role does computer play in CMM?

17

iind year.doc

Documents