IPR 3105 Moderns a... hy 4 “gia outish University of Science and Technology wk \ Deprctovent of Mechanical and Production Engineering 3. Se. in Indistrial and Production Engineering "Year 1" Semester Finat Exansination (Fall 2046) Course Noo IPE 3105 Course Title: Modern Machining Processes Viste. 9 (three) hours Puli Mates: 74 Spn4t a EBD x Thor are 7 (SEVEN) Questions, Angver any § (FIVE) Questions fo - 15 ys ‘The figures in the margin indicate full marks. 5p IE ty 7 a : te TINY RT raditional machining processes «re characterized. (2) (6) hematic diagram explain the working principle of the Abrasive Jet "B10 its inain process parameters. Machining process retry wachining brittle materials in asingle (4) # the volume of material remuvad in cexp prt of diameter d, and producing an indentation of depth 6 in A brasi ©) Seeich eueves to represent the effet of the following process parameiers on MRR in Abrasive Jet (2) Machining Abrasive flow rate Mixing ration end OZ)IN4 marks} ied based on mechanical and chemical & (2) 4) How are nontraditional machining processes class electro-mechanical energy used in performing the process? 5) With the help of a simple schematic diagram explain the working principle and mechanisms of 6 tnatrial removal in USM. Indicate the ranges of frequency and amplitide of vibration of he particles, ©) Dave the expression forthe material removal rate in USM if et any moment of time there isan 4) average of ‘n’ grits impacting on the machining surface and the tool is vibrating at a frequency of P . Assume that the grit is impacting the work 4 sphicrical shape bulge of diameter d; to produce an indentation of depth per impact. 4) Explain how the ultrasonic vibrations are produced by the unsducer and wansmited through the (3) imple sketch to substantiate your answer, ‘hota to the tool in USM, is$5. 4 edt a) Mention the specific upptications of the EDM process. 'b) With the help of Fig. 1 explain the basic working principle of the EDM process. —— gf diac tall +" ig ©) Derivesthe expression for the MRR it tern ofthe V1 testurand the proportionality constant. (2) 4) Mention the different parameters which characterize the waveform in the EDM process. (25) ) What would you suggest to prevent the overcut and the taper cut phenomena inherent to the EDM (135) process? z Q4. [14 marks} 8) Discuss the similarities and dissimilartics of the process characteristics of EBM and LEM (3) processes. ‘Justify their common classification as ‘electro-optical-thermal processes" bb) With a series of simple sketches explain the gradual process of material removal starting fiom the ~ (3) localized heating until the final stage of ejection of the vaporized material in EBM process, ¢) With the help of Fig. 2, explain the working principle of the Electron Beam gun in terms of (8) generation of free electrons, their acceleration to high velocity and further maneuvering of the beam for machining applications,(PR 2105- Modern Machining Processes High vottaga 4 = supaly to cathode | ——» bias grid vacuum throtle valve Port for vacuum +—— por for diffusion pump Sp saige - magnetic lens 54 * lighting system for > telescope for aignment alignment - > aperture - eectromagnetic : . = coils. + ee dct———* detector % eer calls f - Fi . [14 marks}, a) What does laser stand for? Q) ‘Which property of laser makes it possible to focus beam using optical lenses? 5) With a schematic sketch of the energy bands of stoms explain the ‘asing process’ to form the (8) laser beam through ~ Explain the terms: population inversion, stimilated emission ©) With the telp of Fig. 3 explain the working principle of solid-state laser beam equipment for (5) machining application, Caps i {1 5kV Rubyrod +ge marks] YA tn ECM the applied potential difference has to overcome the ade as well a atte cathode, Mention these resistances which ease patent in resistances or potential drops at (2) ial drop, al machining setup wed (5) ') Withthehelp of Fig. 4 explain the full working eycle of the eletrochemie for dciling S Pressure —Lpauge : Loa i tL “J Ni Hh 7 | supply certiuge en Fow conta Pressure relief valve 4 | studge Fiters By {0 Fig. 4 ) In an alloy of ‘x’ elements the atomic weights are given as As, Az, ., Ae With valency during (6) clectrichemical dissolution as v1, V2 » coe, Vwe The weight percentages of different clements ate, .. 6 (in decimal fraction). Derive the expression forthe Material Removal Rate (MRR) in terms of A, vi, eh, p (density of the alloy) and F (Faraday's constant, 4) Mention any six ofthe processing parameters with the ranges oftheir values or materials used @ 2) WIM and AWIM can be achieved using different approaches and methodologies, list these (3) approaches and methodologies b) Derive th expressions forthe power consumption and MR in Chemical Milling proces, Use the (4) standard symbols for the waler pressure, water density, diameter of the orifice, discharge coefficient of the orifice andthe proportionality constant tobe used in the two expressions, ©) Schematic setup of AWIM is shown in Fig. 5. Label the digram and explain the working (4 i)a peneip Pencip OF the Set-up appted tor AWIM Fig. 5 Fig. 6 shows a section ofthe eut generated by an AWJM. As indicatein the figure the top of th kerf is wider tian the bottom ofthe kerf How to reduce the difference between the top and the bottom widths of the kert? ‘How much is the diameter of the AW1 if the stand-off distance is around I to Smin? END OF PAPER OoVHIVETSILY Of § ff Mees “tence and Tech and Pr ©. in Industrial an ‘duction Engineer ye d Production Engineering rT" Some, 7 r ‘1 Course No: Pe seg Semester Final Bx: ination (Spring 2015) /- ime: 3, (three) hours. There aze 3 ( The fj bree) Questions, Answer any2 (Ivo) Questions igures in the margin indicate ull mark atk 1. @) Describe Mag clic Abrasive Finish ig process with necessary sketches. to) Ci deulaie the power densit following p and) ameter ‘The laser power in 10 KW with a beam diameter of 12 pm, divergence angle of 2.5° duration of 19 ps, The m hining constant is 0.8 and evaporation energy of eriat is 0.02 Wémm? with a thickness of 2 anm. The fold lowing equations can used for caleulstion ‘ ACiby i TE, (Py@)=h Les Write down the advantages and applications of Electron Beam Machining Ap) Derivean expression far Volume Removal Rate of Hlecten Beam Machining pro 4 Jo Briefly describe Plasma Are Machining process with nevessary sketches Of Differentiate between transferred and non-tean Why the machining rate increases with Air red Plasma Are Machining procs ma Ate Machining Course Title: Modern Machining Process ining process (6)B There are FIVE questions in this section. Answer any FOUR ‘sing important elements. [06} Gia. Briefly explain the working principle of an AIM sho in AJM process? What are the effects of SOD on machining accuracy 3 Derive an expression for material removal rate by AJM. eria in nachining brittle m (5 Ja! With the help of sketches, describe the different types, of water and abrasive patticles mixing chamber. j é” Derive an expression for material removal rate (MRR) in machining ductile (05%5] materials by Ultrasonic. fs = vu oy Briefly explain the working: principle of an Electrochemical Machining [06] showing important elements. ‘electrolyte flow method used in BCM giving (05% f Explain the various types of their relative merits and applications. Describe the factors that should be CM : considered in selecting an elecirolytein at are the characteristics required for a good electrode [06] 7 140 kgima, le it size= 16mnioron, Find out the time required ti Derive a theoretical relationship for the determination ofthe mt of an alloy in Electrochemical Machining (ECM). What are the functions of an electectyte? Explain the effect ofelectrolyte fw arrangement on MRK in Eicctiocheanital Machining (ECM) a emmaverial weraoval ete expression fo With the help of neat sketches, explain the working principle of Wire Elec | Discharge Machining. What are the funetios of dielectric fuidin EDM? |__How the MRR can be contolled in Becton Beam Machining (EBM)? W1 ‘vacuum is needed! and what isis order in BBM operations? Explain brietly With a Beam Ma: {cher ‘With the Machinin: selup, explaia the principles of operation of Laser (02!Figure for Q.5 (b) Figure for Q5 (a)¢ : wad Production king ‘vial and Semester Higa po sri Prattsetion Kags amination (Pall2919) Como Title: Moder Machining Processes Fall Marks: 20 Fe (Seven) Questions, Aa a Q 6) Hove ste the modem erach : Arse of muster h machining processes eon any 5 (Rive) Que dicate iar he wrargi-— ig processes clssiticd? dt Explain the onwentional ones, Fb, Find out the con ition far which Abrasive Jet Machining (AJM) witl prockace 2 qual evi rei bot for eaclled bitle materials tive thing primiple of a Water Let lac inmportont clesneis. Lis) thea Machining ining! showing x Jel ns oF Aba ayes and app Uvasonie Machining, tas sting, pioriple ni an Bleetrochearieal b working juinciple af (EDM) shining eleva, List he ed Yr EDM ope an cope jing relaxation chveuit, d hanging resi a wl What Win ng ation of BM, reuss the effects of Ah ate Pa estes nstbe eoeans Ba mre we ath aun and Goa Witla net eho letv uf he setup eaplaiy thes j epttelion of heir | a ining NM) the aioe ini 2p : Beste it pace fas ft ! phases tie u | ncase BHA 'cyg0 oO (Abstanaléah Usivesity of Science and Technology Degarennt of Mestancal& Produeion Bnginczring B.Sc. in Indhusirial & Production Engineering (IPE) Year, 1" Semester Binal Examination (Spring 2013) Course Alo, : PE 3105 Course Title: Medern Mack Time: Snows Processes ‘Futh Marks: 10 2) questions in (on) te Sept simple sketch, describe ths working ipl af Abrasive Hot ealvantges and imitations 00 AIM e407 cts of the fllowing praneters on working afl eaoial in AIS () Ge y det y * - 1d of disouce (SON) Df Water ft Mochining (WIM)? Wte"assote on the (97 vipmeat asd in WIRE Give the yea appcstion Juctits (07) ik sia pl eval. sana, Why da ibe ductile mtv erode less pest? act, talnovaeds (07) saatenls in USL ih clctuyie in ECM thielly explain the (07) A crt vio sel by » Sn ECA giving ther relative: wins i” sheds used MY lecuolt applications: elly explain tes workin iv gingestet eemevts, Wat rss fe eet a - £) asap elon set A pow coupes wearing the choice o} [87 Mh tad cmd wanes i one erred ar ef Yue (OA Ie nly of HEDIATae Bocia 2080 fee MUR 201 ) taaded 2 Traduelon Cagiaeesiant yin sa {ial 2042) «fos itadarn Wlacbining Processes i il darks: 70 i Aasworanny 5 (ise) questions of der aachi ges cnmmpared (0 the [07 a we ufiets of SOD cn wacinag aeoueey AIM bit byitde materials (071 oval aces (HAR ia acting syn herding pve of ater feta IS [07] ofabexive paticles and [071 * a ef WIM). a Qh n bei ss fg Matt in nucining of tie ten by Olrsconie (077 ie 1 tie work ping af Ele gehen ie wrinalied ost fa 7 erat cs rij in ECE auple vet debe an (A