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Test report of Production Engineering

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Score Overview Subject wsie Question wise Time wise

Compare with Toppers Solution Difficulty Level Rank

Subject: MELanguage: English

Q.1

achieve directional solidification

reduce possibility of blow holes

reduce the freezing time

increase the smoothness of cast surface

Solution

A chill is used to promote solidification in a specific portion of castingmould. It can be strategically placed to help in directionalsolidification.

Chills are used in hole plates can be used

Correct

Your Ans a

Correct Ans a

Time (Secs) 5

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Q.2

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5 litre

10 litre

15 litre

20 litre

Solution

The neutral flame is commonly used for welding of mild steel. Inneutral flame, the ratio of oxygen to acetylene is oneacetylenemixture is one. So, oxygen consumption = 10 litre

In gas welding of mild steel using an oxyacetylene flame, the totalamount of acetylene consumed was 10 litre. The oxygenconsumption from the cylinder is

Unattempted

Your Ans

Correct Ans b

Time (Secs) 24

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Q.3

Lower nucleation rate

Higher nucleation rate with lower growth rate

Higher nucleation rate with higher growth rate

Lower growth rate

Solution

Sol. (b)

Fine grain size during solidification of metal is achieved by

InCorrect

Your Ans c

Correct Ans b

Time (Secs) 49

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Q.4



Lower hardness by transforming austenite to pearlite

Lower hardness by transforming martensite to pearlite

High hardness by transforming austenite to martensite

High hardness by transforming martensite to pearlite

Solution

Sol. (b)

Tempering process is used in steels to achieve

Correct

Your Ans b

Correct Ans b

Time (Secs) 19

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Q.5

Makes the tool stronger

Increases shear angle

Makes the cutting edge sharper

Increases the chip thickness

Solution

Sol. (c)

Cutting force is reduced if rake angle is positive because positiverake angle

Unattempted

Your Ans

Correct Ans c

Time (Secs) 25

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Q.6



Solution

Clearance angle = 90 – (60 + 20)

In the figure shown below. The clearance angle (in degree) is______

Correct

Your Ans 10

Correct Ans 10

Time (Secs) 16

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Q.7

Solution

MRR = TdV = 0.8 × 1.2 × 60 × 10MRR = 57600 mm /min

A steel workpiece is turned on a lathe at 60 m/min cutting speed,0.8 mm/rev feed and 1.2 mm depth of cut. The metal removal rate(in mm /min) is ______ .3

3

3

Correct

Your Ans 57600

Correct Ans 57500 | 57700

Time (Secs) 44

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Q.8



Relief face of tool

Rake face

Nose of tool

Cutting edge

Solution

Sol. (a)

Flank wear mainly occurs on

InCorrect

Your Ans b

Correct Ans a

Time (Secs) 12

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Q.9

400%

300%

200%

100%

Solution

In Taylor tool life equation VT = C, n = 0.5 and C = 300. Thepercentage increase in tool life when the cutting speed is reducedby 50% is

n

Unattempted

Your Ans

Correct Ans b

Time (Secs) 11

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Q.10

Solution

Tolerance = 0.05 – (–0.05) = 0.1 mmTolerance = 1000 microns

Unattempted

Your Ans

Correct Ans 100

Time (Secs) 3

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Q.11

Solution

A shaper having length of 200 mm has 30 number of doublestrokes per minute with ratio of cutting time to time of return equalto 3/2. The cutting speed is _____ m/min.

Unattempted

Your Ans

Correct Ans 9.9 | 10.1

Time (Secs) 8

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Q.12



small components

large components

identical components in large number

medium size components

Solution

Sol. (a)

Drop forging is used to produce

Unseen

Your Ans

Correct Ans a

Time (Secs) 0

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Q.13

BCC form of iron

FCC form of iron

Pure iron with very low carbon

Intermetallic compound iron carbide

Solution

Sol. (b)

Austenite is the

Unseen

Your Ans

Correct Ans b

Time (Secs) 0

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Q.14



1.26

2.51

48

151

Solution

The cutting velocity in m/sec., for turning a work piece or diameter100 mm at the spindle speed of 480 RPM is

Unseen

Your Ans

Correct Ans b

Time (Secs) 0

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Q.15

0.2%

6.67%

2%

1.2%

Solution

Sol. (c)

Maximum carbon content in steels is up to

Unseen

Your Ans

Correct Ans c

Time (Secs) 0

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Q.16



small components

large components

identical components in large numbers

mediumsize components

Solution

Droping forging is used to produce large number of identicalcomponents. In this process, a shaped die is used, with one halfbeing attached to the hammer and the other half to the axvil . It is amass production technique.

Drop forging is used to produce

Unseen

Your Ans

Correct Ans c

Time (Secs) 0

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Q.17

30 s

36 s

1 minute

45 s

Solution

A 150 mm long, 12 mm diameter 304 stainless steel rod is beingreduced in diameter to 11.5 mm by turning on a lathe. The spindlerotates at N = 400 rpm and the tool is travelling at an axial speed of200 mm/min. The time taken for cuttiing is given by

Unseen

Your Ans

Correct Ans b

Time (Secs) 0

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Q.18



6 mm

12 mm

25 mm

44 mm

Solution

The amount of offset of tail stock for turning taper on full length of ajob 300 mm long which is to have its two diameters at 50 mm and38 mm ultimately is

Unseen

Your Ans

Correct Ans a

Time (Secs) 0

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Q.19

110 mm/min

35 mm/min

6 mm/min

60 mm/min

Solution

A milling cutter of 70 mm diameter with 12 teeth is operating at acutting speed of 22 m/min and a feed of 0.05 mm/ tooth. The feedper minute is

Unseen

Your Ans

Correct Ans d

Time (Secs) 0

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Q.20

poor casting design

faculty mould flask

lower strength of the solidified metal

higher moisture in the moulding sand

Solution

Sol. (d)

Blow holes in sandcasting are caused by

Unseen

Your Ans

Correct Ans d

Time (Secs) 0

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Q.21

Pouring hot metal into the mould

Non uniform thickness of walls joining in a casting

Poor refractory property of the moulding sand.

Low thermal conductivity of the moulding sand.

Solution

Sol. (b)

Hot tear is sand casting is caused by

Unseen

Your Ans

Correct Ans b

Time (Secs) 0

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Q.22



Solution

In an orthogonal turning of mild steel. The cutting velocity, feed anddepth of cut were 120 m/min, 0.25 mm/rev, and 2 mm respectively.When the cutting force of 800 N was applied. The specific energyconsumption for the turning operation (in J/mm ) is_____.3

Unseen

Your Ans

Correct Ans 1.6

Time (Secs) 0

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Q.23

Solution

Sol. [2]

In ASA, the tool nomenclature is 88561023 mm, then the sidecutting edge angle for the tool (in degree) is _________.

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Your Ans

Correct Ans 2

Time (Secs) 0

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Q.24



Solution

A molten liquid metal having spherical shape with 2 mm radiustakes 8 seconds to solidify. The same molten metal drop withdouble the radius will take ______ seconds to solidify.

Unseen

Your Ans

Correct Ans 32

Time (Secs) 0

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Q.25

Any complex shape can be obtained

Cost of the pattern is low

Very thin sections can be readily made

Any size of casting can be obtained.

Solution

Sol. (c)

Main advantage of using shell moulding is

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Your Ans

Correct Ans c

Time (Secs) 0

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Q.26



The use of AC welding with nonconsumable electrodes

The use of DC welding with consumable electrodes

The use of AC welding with consumable electrodes

none of the above

Solution

Sol. (b)

Arc blow in manual metal arc welding is caused by

Unseen

Your Ans

Correct Ans b

Time (Secs) 0

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Q.27

Solution

In a wire drawing operation, diameter of steel wire is reduced from8mm to 7 mm. The mean flow stress of material is 250 MPa. Theideal force required for drawing (in kN) is _____.

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Your Ans


Time (Secs) 0

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Q.28



Solution

A blank of width 15 mm width and 25 mm length is cut from a 2 mmthick strip., if the ultimate shear strength of metal strip is 300 MPa.The blanking force required is _____ kN.

Unseen

Your Ans

Correct Ans 48

Time (Secs) 0

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Q.29

Solution

A cup of 120 mm diameter and 50 mm height is to be drawn usinga blank. The required blank diameter will be _____ mm.

Unseen

Your Ans


Time (Secs) 0

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Q.30



Lowcarbon steels

Alloy steels

Mediumcarbon steels

Highcarbon steels

Solution

Sol. (b)

Nitriding process is used to increase surface hardness for

Unseen

Your Ans

Correct Ans b

Time (Secs) 0

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Q.31

(1 0 0)

(1 1 0)

(1 1 1)

(1 0 1)

Solution

Miller indices for the hatched plane in the below unit cell will be

Unseen

Your Ans

Correct Ans b



Time (Secs) 0

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Q.32

Solution

During an orthogonal cutting with rake angle of 12°, the chipthickness ratio was found to be 0.4 and width of cut and uncut chipthickness were 2 mm and 0.5 m respectively. If the yield shearstress of work material is 250 MPa, the shear force on total is_____ N.

Unseen

Your Ans


Time (Secs) 0

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Q.33



Solution

Sol. (d)

Unseen

Your Ans

Correct Ans d

Time (Secs) 0

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Q.34



15 mm

20 mm

25 mm

30 mm

Solution

A hole is to be punched in a 15 mm thick plate having ultimateshear strength of 2.5 N/mm . If the allowable crushing stress in thepunch is 6 N/mm , the diameter of the smallest hole which can bepunched is equal to

2

2

Unseen

Your Ans

Correct Ans c

Time (Secs) 0

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Q.35

Solution

A metallic sheet is reduced from an initial thickness of 10 mm to afinal thickness of 7 mm in a single pass rolling with rollers ofdiameter 300 mm. The angle of bit (in degrees) would be _____.

Unseen

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Time (Secs) 0

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Q.36

Solution

The casting shown in figure is to be made using steel which has ashrinkage allowance of 21 mm/m. Assuming shrinkage allowanceonly, the dimension of the pattern will be. (All dimensions in mm).

Unseen

Your Ans

Correct Ans a

Time (Secs) 0

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Q.37



Solution

A sprue is to be designed for a casting to feed the molten metal ata rate of 10 kg/sec. The density of liquid metal is 8000 kg/m andthe height of pouring basin and height of sprue are 6 cm and 9 cmrespectively. Assuming sprue to be conical shape, the diameter ofsprue at top end i.e. larger diameter will be _____ cm.

3

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Your Ans


Time (Secs) 0

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Q.38

Solution

A sprue is to be designed for a casting to feed the molten metal ata rate of 10 kg/sec. The density of liquid metal is 8000 kg/m andthe height of pouring basin and height of sprue are 6 cm and 9 cmrespectively. Assuming sprue to be conical shape. The diameter ofsprue at lower end will be _____ cm.

3

Unseen

Your Ans


Time (Secs) 0



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Q.39

43 mm

38.2 mm

36.1 mm

35.7 mm

Solution

A strip of metal of dimension 40 mm × 25 mm × 100 mm is reducedto 10 mm × 100 mm × 100 mm between two flat dies in a forgingprocess. If the coefficient of friction is 0.25, the length from thecentre of strip along length upto which stricking exist is

Unseen

Your Ans

Correct Ans c

Time (Secs) 0

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Q.40

4 and 12

6 and 6

6 and 12

6 and 9

Solution

Sol. (c)

Average number of atoms and coordination number for a crystalhaving HCP structure are respectively

Unseen

Your Ans



Correct Ans c

Time (Secs) 0

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Q.41

Solution

During an orthogonal turning process with a tool designated as : 7 ? 6 6 8 20 1 mm, the tangential and thrust cutting forcewere 1200 N and 500 N respectively. The side rake angel (indegrees) is _____.

Unseen

Your Ans


Time (Secs) 0

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Q.42



Solution

During an orthogonal turning process with a tool designated as : 7 ? 6 6 8 20 1 mm, the tangential and thrust cutting forcewere 1200 N and 500 N respectively. The coefficient of friction atthe rake face is _____

Unseen

Your Ans


Time (Secs) 0

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Q.43



Solution

Sol. (a)

Unseen

Your Ans

Correct Ans a

Time (Secs) 0

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Q.44



400 A and 100 V

200 A and 100 V

400 A and 50 V

200 A and 50 V

Solution

Assuming a straight line V – I characteristics for a dc weldingsgenerator, shortcircuit current as 400 A and open circuit voltageas 100 V, which one of the following is the correct voltage andcurrent setting for maximum arc power?

Unseen

Your Ans

Correct Ans d

Time (Secs) 0

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Q.45



39.5º

42.25º

47.75º

50.5º

Solution

In an orthogonal cutting, rake angle of the tool is 20º and frictionangle is 25.5º. Using Merchant’s shear angle relationship, thevalue of shear angle will be

Unseen

Your Ans

Correct Ans b

Time (Secs) 0

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Q.46



Solution

Sol. (c)

Unseen

Your Ans

Correct Ans c

Time (Secs) 0

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Q.47

Solution

Sol. (c)

Which of the following is clearance fit

Unseen

Your Ans



Correct Ans c

Time (Secs) 0

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Q.48

Drilling, reaming and grinding

Drilling, boring and grinding

Drilling, reaming and lapping

Drilling, reaming and electroplating

Solution

Drilling, reaming and grinding are machining processes used forgiving final shape to the component, whereas lapping andelectroplating are surface finishing processes used to provided agood surface finish to the machine component.Reaming is a sizing operation that removes a small amount of metalfrom a hole already drilled.

Which one of the following processing sequences will give the bestaccuracy as well as surface finish?

Unseen

Your Ans

Correct Ans c

Time (Secs) 0

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Q.49



Solution

EDM is used for shapping alloying steel and tungsten carbide dies,used for moudling, forgin, extension, wire drawing or suitable mouldcavities, press tools and to given any intricate shape or profile.ECM is used for machinary difficult to machine materials andcomplex shaped parts. Laser can make holes in a wide variety ofmaterials such as plastics, ceramics and many metals and alloys.USM can be used for drilling circular or noncircular holes in veryhard materials.

Match List I (Unconventional machining process) with List II(Typical application) and select the correct answer:

Unseen

Your Ans

Correct Ans b

Time (Secs) 0

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Q.50



0°

30°

45°

90°

Solution

Angle between directions having miller indices [1 0 0] and [1 1 0] is

Unseen

Your Ans

Correct Ans c

Time (Secs) 0

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Q.51



Solution

In an orthogonal metal cutting process. The chip thickness ratiowas found to be 0.35, the rake angle was 10° and the chip flowvelocity as 2.5 m/s. If the mean thickness of primary shear zone is20 microns, the shear strain rate (in s ) is _____ × 10 .–1 4

Unseen

Your Ans


Time (Secs) 0

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Q.52



1.04 min

1.96 min

2.00 min

2.09 min

Solution

The time required to turn a mild steel rod from 5 cm diameter to 4.9cm a length of 10 cm if the cutting speed is 30 m/min and feed is0.25 mm/revolution is

Unseen

Your Ans

Correct Ans d

Time (Secs) 0

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Q.53

Solution

A hollow casting has to be produced by a cylindrical core of 120mm diameter and 180 mm height. The density of liquid metal is11300 kg/m and the density of core material is 1300 kg/m . Theupward lifting force on the core will be _____ N.

3 3

Unseen

Your Ans




Time (Secs) 0

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Q.54

Solution

Sol. (a)

Unseen

Your Ans

Correct Ans a

Time (Secs) 0

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Q.55



Solution

Two steel sheets of 1 mm thickness are resistance welded in a lapjoint with a current of 800 amp. for 0.2 seconds. The effectiveresistance of the joint is 120 micro ohm. The joint can beconsidered as cylinder of diameter 10 mm and 1.5 mm height. Theheat required to melt steel is 0.1 J/mm .Heat lost to surrounding is _____ Joules.

3

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Time (Secs) 0

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Q.56

Solution

A since bar has a length of 250 mm. Each roller has a diameter of25 mm. During taper angle measurement of a component, theheight from the surface plate to the centre of roller was measuredas 100 mm. The taper angle (in degrees) is_____

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Q.57

1.31 mm

2.62 mm

5.25 mm

6.00 mm

Solution

The arc lengthvoltage characteristic of a D.C. arc is given by theequation, V = 24 + 4L, where V’ is arc voltage in volts and ‘L’ is arclength in mm. The static voltampere characteristic of the powersource is approximated by a straight line with a no load voltage of90 volts and short circuit current of 600 Amp. The optimum arclength for maximum power is

Unseen

Your Ans

Correct Ans c

Time (Secs) 0

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Q.58



13 ± 0.07 mm

13 ± 0.11 mm

12.99 ± 0.11 mm

12.99 ± 0.07 mm

Solution

Sol. (c)

Unseen

Your Ans

Correct Ans c

Time (Secs) 0

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Q.59

Solution

4.5 mm thick sheet is rolled with 250 mm diameter rolls to reducethickness without any change its width. The friction coefficient atthe workroll interface is 0.1. The minimum possible thickness ofsheet that can be produced in a single pass is _____ mm.

Unseen



Your Ans


Time (Secs) 0

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Q.60

Solution

Unseen

Your Ans

Correct Ans b

Time (Secs) 0

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Q.61

Solution

A gating ratio of 1 : 3 : 4 is used to design a gating system. If thesprue area is 3 mm , then the gate area will be _____ mm .2 2

Unseen



Your Ans

Correct Ans 12

Time (Secs) 0

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Q.62

Solution

Unseen

Your Ans


Time (Secs) 0

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Q.63



200 J

400 J

600 J

800 J

Solution

In a blanking operation to produce steel washer, the maximumpunch load used is2 × 10 N. The plate thickness is 4mm and percentage penetrationis 25. The work done during this shearing operation is

5

Unseen

Your Ans

Correct Ans a

Time (Secs) 0

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Q.64

Solution

A hole of 40 mm diameter and 50 mm depth is to be drilled in mildsteel component. The cutting speed can be taken as 65 m/min andthe feed rate as 0.25 mm/rev. Assuming lip angle of drill is 118°.The machining time___minutes.

Unseen



Your Ans

Correct Ans 0.5

Time (Secs) 0

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Q.65

Normal time + Allowances

Observed Time + Allowances

Observed time × Rating factor

Normal time × Rating factor

Solution

Normal time = observed time × Rating factorStandard time = Normal time + Allowances

In Industrial engineering, the standard time is equal to

Unseen

Your Ans

Correct Ans a

Time (Secs) 0

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Q.66

process charts

flow diagrams

manmachine operation charts

therbligs

Solution

Sol. (d)

A SIMO chart should be used with

Unseen

Your Ans

Correct Ans d

Time (Secs) 0

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