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M.E. DEGREE EXAMINATION, NOVEMBER/DECEMBER 2010 Elective Engineering Design ED 9271 RAPID PROTOTYPING AND TOOLING (Common to M.E.

. Product Design and Development and M.E. Computer Aided Design) (Regulation 2009) Time : Three hours Maximum : 100 Marks Answer ALL questions PART A (10 2 = 20 Marks) 1. List any four advantages of RP in product design and development. 2. How does digital prototyping differ from virtual prototyping? 3. What is called road width in fusion deposition modeling? 4. Discuss any four limitations of laminated object manufacturing. 5. Describe Net shaped manufacturing. 6. What is meant by beam energy in electron beam melting? How is it controlled? 7. Name any four different types of data formats. 8. Describe Adaptive slicing. 9. Sketch the advantages of break-away support system. 10. How does aerospace technology make use of rapid tooling applications? PART B (5 16 = 80 Marks) 11. (a) (i) Explain, with suitable example, how rapid prototyping and tooling are the good examples as part of computer integrated manufacturing. (8) (ii) Develop a virtual prototype for hydraulic turbine. Draw suitable process flow diagram and explain. (8) Or (b) (i) Draw the outline showing the history of development of RP systems around the world. (8) (ii) List any eight important benefits of RP & T. (8) 12. (a) (i) Discuss the benefits and limitations of stereolithography system. (8) (ii) Explain the process of building an RP of flange coupling made of polymeric sheets. (8) Or (b) (i) Make a note on the process of making a rapid prototype of ball bearing assembly. (8) (ii) Discuss on any four types of materials, their applications and the processes in which they are used. (8) 13. (a) Explain, with suitable sketch, the process of manufacturing a prototype of circular disc made of ceramic material. (16) Or (b) Sketch the process of electron beam melting, its application and limitations. (16) 14. (a) (i) How is the design data processed in RP technology? Explain with suitable example. (8) (ii) Discuss on contour data processing to minimize the stair-case effect in RP products. (8) Or (b) (i) Discuss the CAD model preparations. (8) (ii) Describe any three types of geometric modeling techniques. (8) 15. (a) (i) Discuss the process of making a rapid tool for blow moulding. Assume your own example as product. (8) (ii) Compare Direct and Indirect tooling with classic examples. (8) Or (b) (i) Discuss any four types of finishing processes adopted for rapid prototypes. (8)

(ii) Write notes on the applications of RP&T in the following fields : (1) Medical field (2) Automotive engineering (3) Electronic industries (4) Architecture.

M.E. DEGREE EXAMINATION, JUNE 2010 Elective Engineering Design ED9271 - RAPID PROTOTYPING AND TOOLING (Common to M.E. Product Design and Development and M.E-Computer Aided Design) (Regulation 2009) Time : Three hours Maximum : 100 Marks Answer ALL Questions PART A (10 2 = 20 Marks) 1. Give two critical applications of virtual prototyping. 2. List the steps involved in product development. 3. Name the materials suitable for FDM process. 4. State the limitations of LOM process. 5. Name any two products that can be made through 3-D printing. 6. What is laser sintering? 7. Define the term part orientation. 8. What is support structure design? 9. State classification of rapid tooling. 10. What is meant by soft tooling? PART B (5 16 = 80 Marks) 11. (a) Discuss the various stages in the development of RP systems highlighting the merits and limitations. Or (b) In detail explain the need of Rapid Prototyping and tooling in product development. 12. (a) Describe LOM process and discuss the effects of process parameters on the quality of the final product. Or (b) Explain the working principle and details of process parameters of an FDM machine. 13. (a) Discuss with diagrams the selective laser melting and electron beam melting process. Compare and contrast these processes. Or (b) Explain how SLS process can be used to produce direct and in-direct prototypes. 14. (a) When is reverse engineering applied? In detail discuss the steps involved in Reverse engineering. Or (b) Explain the significance of part orientation; support generation and slicing with reference to RPT. 15. (a) Explain the concept of Bridge tooling with a case study. Or (b) Discuss how RPT can be used for the production of rapid tooling for aerospace and electronic industries.