1oME848

USN

Eighth Semester B.E. Degree Examination, June/July 2014

Design for Manufacturing and Assembly

Max. Marks:100

Time: 3 hrs.
Note: Aruswer any FIVEfull questions, selecting
atleast TIYO questions from each parL

PART _ A
a.

b.

Illustrate the different types of fits.

(09 Marks)

4 parts with the following dimensions are to be assembled in randorn What should be the
tolerance on the assembled length? Also, what is the dimension of assembled length?
Part 1:

2fi2:o631r:rn

Part2:18.91+0.03

mm

Part 3: 62.1?13'3; mm
Part 4: 46.25 + 0.04mm.
c.

2a.
b.

a.
b.

(06 Marks)

Discuss the .relationship between attainable tolerance grades and different machining
processes.

(05 Marks)

What is flatness? Explain the procedure for determining flatness.

Illustrate the various ter,rns used in connection with surface finish.
Explain any 2 terns used to describe surface roughness.

(08 Marks)

interchangeability.
assembly.

Marks)

(04 Marks)
(12 Marks)

Discuss the concept of

Explain the term selective

a. In a pressure

(08

(08 Marks)

measurement experiment, the following values are obtained. Calculate the

mean, mean deviation and standard

deviation.

(10 Marks)

Pressure,lfa Frequency
J

9.8
9.9
10.0

b.

4
8

10.1

t0.2

What is process capabllity? Explain the process capability indices Co and Cpr.

af2

(10 Marks)

IOME848

5a.
b.

6a.
b.

."I*tk,ilrt*

Iltustrate the use of cored hores to

of holes.
Illustrate the match-plate patterns used in sand castiig.
Briefly explain the design rules for producing good clstings.

(04 Marks)
(06 Marks)
(10 Marks)

Illustrate the various design considerations for thread cutting (external),

drilling, milling and
tapping operations.
eiifaln Uiiefly, how reduction in machinfug area, can be achieved, in turning

nro.JlX.*"tut'

(02 Marks)

7a.
b.
c.

8a.
b.

Discuss the major phases of design process.

List the basic principres that will help the designer in speciffing the product Marks)
and its
components for
(10

economic production.
Discuss the main considerations (any 3) in the design of weldments.

(06 Marks)

Explaiir in detail the materiar selection in product design.

Make a comparison of elastic modulus foi different clisses
ofmaterials.

(05 Marks)

****d.

(04 Marks)

(15 Marks)

06M8848

ara*

Eighth Semester B.E. Degree Examination, Decemb er 2OlO

Design for Manufacturing and Assembly

Time: 3 hrs.

Max. Marks:100
at
questions,
selecting
Note:1. Answer any FIVEfutl
least two questionsfrom eoch Part.
. IJse of SQL tables ond normal distribution tables is allowed.

PART - A

1a.
b.
c.
d.

2a.

b.

3a.
'b.

(08 Marks)
classify fits. Explain different types of fits, with an example each.
(04 Marks)
Differentiate between tolerance and allowance'
(04 Marks)
Explain Indian standard system of limits and fits (IS 919 and2709)
Give the relationship between attainable tolerance grades and different machining processes'

(04 Marks)

Give the symbols used in geometric tolerancing, to describe the form of a feature, profile
(10 Marks)

and other related features.

A 25 mm H8-fl/ fit is to be checked. The limits of size for H8 hole are 25.030 mm low limit
equal to basic size. The limits of size for the f7 shaft are high limit 24.970 mm and
Zi.gSO mm. Taking gauge maker's tolerance to be l0% of the work tolerance, design plug
(10 Marks)
gauge (gap gauge) to check the fit.
(08 Marks)
What are the elements of a surface texture? Explain with a neat sketch'
The surface finish on the milled surface is not to exceed 5 pm Ra with a cut off length
Z mm, machining allowance 0.5 mm and direction of lay parallel. How will you represent it
(02 Marks)
on a
peaks
valleys,
and
In the measurement of surface roughness, heights of 20 successive
measured from a daturn are as follows: 45,25, 40,25, 35, 16,22, 40,25,34,25, 40,20,36,
28,18,20,25,30, 38.
If these measurements were made over a length of 20 mm, determine CLA and RMS values
(r0 Marks)
ofthe surface.

drawing?

4a.
b.

(10 Marks)
What are the 7QC tools in SPC? Explain them.
A control chart has been used to monitor a certain characteristic. The process is sampled in a
subgroup size of 4 at an interval of 2 hours. X -chart has 3o control limits of 121 and t29

with the target value of X =125.

i) If the product is sold to a user, who has a specification of 127 + 8, what percentage of
the product will not meet the specification, assuming normally distributed output?
ii) If the target value of the process can be shifted, without eflect on the process standard
deviation, what target value would minimize the amount of product being outside the
specifications?

iii) At this new target value, what

percentage of the product

will not meet the specification

(10 Marks)

requirement?

PART - B

5 a. Explain the major design phases (seven phases) in morphology of design. (12 Marks)
b. What are the principles of casting design that must be observed to obtain sound castings?
(08 Marks)
I of2

06ME848

6 a.
b.

7a.
b.

What are the design factors, considered in machining and welding?

Explain the following terms, related to a component design:
Run out.
ii) Reduction of machined areas.
iii) Simplification by separation.
iv) Simplification by amalgamation.
v) Provision for holding the work piece.

Explain.

(t0Marks)

i)

(10 Marks)

Explain the composition properties of various materials used in design.

(10 Marks)

A cast iron bearing bracket is shown in the figure Q7 (b). Indicate the preferred parting line
and any necessary sand cores. Offer a design modification that
need for sand cores.

will

reduce or eliminate the

(10 Marks)

Fig. Q7 (b)

The hub shown in figure Q8 is made of carbon steel. Discuss the steps of planning the process to
manufacture this part. Draw the operation sheet also.
(20 Marks)

Ctmrnl.
ar(.t

*[

dfracrr3t cr78 Ln
Fig. Q8

**,t**

2 of2

rat

06ME848

USN

Eighth Semester B.E. Degree Examination, June/July

20ll

Design for Manufacturing and Assembly

Time:3 hrs.

Max. Marks:100
Note: Answer FIW full questions selecting
at least fWO questionsfrom each part.

PART

-A

c.

With suitable sketcheq explain upper deviation, lower deviation and fundamental deviation.
(05 Marks)
(10 Marks)
What is fit? Explain clearance, interference and transition
(05 Marks)
Write a note on tolerance accumulation.

a.
b.

What is GD and T? Explain any six geometrical characteristics with

Intrepret the following Fig.Q.2(b) :

1a.
b.

fits.

symbols.

(15 Marks)
(03 Marks)

Fie:Q.2(b)

c.
3a.
b.

4a.
b.

5 a.

(02

Define true position tolerance.

Marks)

roughness.

(10 Marks)
Explain the terminology used for surface
With a neat sketch, explain Tomlinson surface.meter to measure surface roughness.l0
Marts)

Explain how process capability helps to measure whether the process under study meets the
(12 Marls)
requirements or
(0E Marls)
Write a note on Kurtosis.

not.

PART

Identify the possible parting line for the lever shown in F

(06

.s(a).

$16
$+o

izo

Fie.Q.s(a).

I of2

Marks)

06ME848
Indicate the preferred parting line and any necessary sand cores for the C.I. bracket shown in
Fig.Q.s(b). Offer a design modification that will reduce or eliminate the need for sand cores.
(14 Marks)

Fie.Q.s(b)

6a.
b.

With suitable example, explain how amalgarnation helps in reducing machining. (06 Marks)
Comment on the undesirable machining feature involved in the shaft design of the subassembly shown in Fig.Q.6(b). Also show a suitable design modification to the shaft and
show an alternative method of securing the gear to the shaft when the gears are finish
machined in stores.
(14 Marks)

Fig.Q.6(b)

7 a. v/ith the help of a block diagram, explain ttre major design phases.
b. Mentionthe factorsto be considered while designing a cast componenl
8 a. Explain the factors which affect the design of a component.
b. Explain any two material selection processes.
,f**:t*

2 ofZ

Marks)
(06 Marks)
(14

(lOMarks)
Marks)

(10

06M8848
USN

Eighth Semester B.E. Degree Examination, I)ecemb er 20ll

Design for Manufacturing and Assembly

Time:3 hrs.

Max. Marks:100
Note: Answer any FIW full questions, selecting
ot least TWO questionsftom eoch part'

PART

-A

Mention the importance of tolerance. fxplain the unilateral tolerance

la.
b.

and bilateral tolerance.

Determine the type of fit for 60mm shaft and hole pair designated H8lf7
Diameter stePs = (50 - 80)

(0E Marks)
'

is:-5.5Doar
IT8 :25 i

IT7:16i

(12 Marks)

Explain the following geometrical characteristics, with symbol and its interpretation:
circularity ii) cylindricity iii) Flatness iv) Runout

i)

3 a. Explain how the Tomilson surface meter can be used for direct measurement
. qualitY.
b.

Exptain the terminologies used for surface rougness'

Write short notes on:

Process caPabilitY

i)

ii)

of

surface
(10 Marks)
(10 Marks)

(20 Marks)

Kurtosis.

PART

(20 Marks)

-B

Define pattern. With the help of a sketch, explain the various pattern allowances.
With skeJches, differentiate between cast and cored holes.
Identify the possible parting line for ahollow bush.

(06 Marks)

6 a. Explain with an example, how length of the twist drill is an important

machining

consideration.
Write a note onthe reduction of machined areas.
Explain how the amalgalnation helps in the reduction of machining areas.

(08 Marks)
(06 Marks)

5a.
b.
c.

b.
c.

Explain the major design phases with the help of a block diagram.

(08 Marks)
(06 Marks)

(06 Marks)

(20 Marks)

8 a. Exptain the following material selection processes:

1) Cost Per unit ProPertY method
ii) Weighted ProPerties method
(15 Marks)
iii) Limits on ProPerties method.
of the
b. With a suitable example, explain how component geometry affects the behaviour
(05 Marks)
component.

*rl***

06ME848

USN

Eighth Semester B.E. Degree Examination, June 2012

Design for Manufacturing and Assembly

Max' Marks:100

Time: 3 hrs.

Note: l. Answer

FrvEfult questions, selecting

at least TWO questionsfrom each parL

2. Missing data if any, ffie be suitably assumed

I a.

PART
Define the following

D Fits

-A

ii) Basic size

iii)

Fundamental deviation.

(06 Marks)

b. State the Taylor's principle for the design of limit guage.

(06 Marks)
c. Determine the dimension and tolerances on flange thickness 'T' as in Fig. Ql (c). (08 Marks)

rt8'3

o'og

- o.o1

Fig.

2a.
b.

c.

3a.
b.

4a.

c.

(c)

Describe a method to find out the flatness of a surface

plate.

(06 Marks)

Describe how a lobed surface is defured mathematically and show the dimensions of the
geometric form ofthe cross section.
(06 Marks)
A cylindrical piece ground on centreless grinding machine when measured by micrometer
screw guage shows the readings to be 20.000 mm. It is found that it only just fits into a truly
circular ring guage of 2A.040 mm diameter and it is uniformly three lobed. Determine the
dimensions of the geometric form of the cross section.
(0E Marks)
Explain the following terms in connection with surface finish measurement:
i) waviness ii) Lay
iii) Envelope method iv) crest line method.
Name and describe any two methods used for measuring surface

roughness.

(08 Marks)
(12 Marks)

The mean value and standard deviation of set of observations have been found to be I00 and
I0 respectively. Determine what percentage of observations will lie between 84 and I 16,
i) above 82
ii) below
(0E Marks)

and

b.

Ql

79.

What do you understand by frequency distribution? What are the common probability
distributions? What are their forms and applications in statistical quality control? (06 Marks)
What is the task of statistical quality control (SQC) and what are the statistical quality tools
available?

I of2

(06 Marks)

06M8848
PART

5a.

-B

Explain with sketches the different possible parting line for casting a hollow bush. What is
most suitable parting line for bush?
(08 Marks)
A cast iron bearing bracket is shown in Fig. Q5 (b). Indicate prefened parting line and any
necessary sand cores. Suggest the design modification that will reduce or eliminate sand

b.

cores.

+6" o*(
6o.

(12 Marks)

rq__--}l

*r1

{i-l

--i

il

+ltto

Fig. Qs (b)

rrti

,t:-;-jry

+ to15f D9\t!1oLEs
r3.)

6 a.
b.

Explain Dowels and Dwelling procedure.

(05 Marks)
Suggest suitable sequence of machining operations to given cast iron plate shown in
Fig. Q6 (b) and suggest a design modification which will reduce machining cost. (15 Marks)

g9.a3

2-s.o6'

lL hlJl o4

' zco ?cD'

r8r-

7 a. write a note on major phases ofdesign.

(08 Marks)
b. Explain the influence of fabrication properties on design in the below mentioned processes: '
i) Machinabilitv ii) castabitity
iii) weldabitity
iv) Polymer processing
(12 Marks)
8a.
b.

Explain:

i)

Cost per unit property method.

ii) Weighted properties method.
Write a note on limits on properties method.

*****
2

of2

(12 Marks)
(08 Marks)