DEPARTMENT OF MECHANICAL ENGINEERING

QUESTION BANK

Subject Code : ME 6005

Subject Name : Process Planning and Cost Estimation
Year/Semester : IV/VII

UNIT-1

INTRODUCTION TO PROCESS PLANNING

PART-A

1. Define process planning. (Dec-2016, April 2017)

2. List the objectives of process planning. (Dec-2017,2018)

3. Categorize the main approaches or methods of process planning.(April 2019)
4. Discuss the various parameters considered in the material selection? (Dec-2017)

5. Write any four cutting tool materials? Order of high hardness to low hardness? (April-
2017)
6. What are the factors consider in during selection of process (Dec-2016)

7. What are the most influential factors in terms of tool performance ?.(Dec 2017)

8. What is bilateral tolerance ? Give examples.(Dec 2017)

9. Interpret the symbol given below (Nov 2018)

10. How is surface finish indicated on an engineering drawing?(April 2019)

11. What are the details required for process planning?(April 2018)
12. Study the drawing and interpret any one geometric tolerance symbol.(April 2019)

13. Summarize the factors influencing process selection.

14. Illustrate the use of drawings interpretation in processing requirement.
15. Prioritize the sort of information can the process planner obtained from the engineering
drawing of the component.

16. Give a procedure for process planning for the manufacture of a component in machine shop.
17. Illustrate the factors considered for selection of machines and tooling's.
18. What are the various steps involved in process selection
19. What are the stages of machine selection process?
20. What are the factors affect process planning?
Part-B
1. Describe the steps or procedures involved in Process Planning. (Dec2018&17)
2. Explain steps in process selection with suitable example. (April 2019)
3. Show the two approaches to Process Planning in the context of CAPP (Computer Aided
Process Planning)? Explain them clearly.(Dec 2017&16, April-2018))
4. Explain with neat sketch and the steps followed for material selection process and methods.
(Dec-2016,April 2019)
5. Explain the various methods involving in process selection with suitable example.
(or)Describe the various procedures followed selecting the appropriate of a manufacturing
process. (April-2017)
6. Explain briefly the factors considered for selection of Equipments for process planning (Dec-
2016 &Dec 2017)
7. Explain the steps (or stages) involved in machine selection procedure for process planning?
8. Explain the basic method employed for selection of cutting tools (Dec 2018&17)
9. What are the constrains in tool selection? With suitable examples (Dec-2016)
10. In the figure interpret the meaning of any two
i) Dimensional tolerance symbols
ii) Form tolerance feature control frames
iii) Surface finish symbols (April 2017)
11. . Discuss the production equipment and tool selection for the component shown in fig.3.
Undercut diameter is 12mm.(April 2018)

12. .Interpret the various symbols given in the drawing.(April 2019)

13. . Prepare an operation and route sheet for the component shown in fig (April 2018)
 UNIT-2

PROCESS PLANNING ACTIVITIES

PART-A

1. What is relation between the tolerance and surface finish.(May-2017)

2. List the information required for process planning.

3. Compose the documents required for Process Planning?(April 2018)

4. List the factors Considered for selecting Process parameter.(Nov 2016&April 2019)
5.
6. What is the different between routing sheet and operations list (May-2017)

7. What is the different between routing sheet and Process sheet. (Dec-2018)
8. What are the main reasons for using Jigs and fixture(Dec-2018& Dec-2017)
10. Classify how milling operations can be classified.
11. Classify the three basic functions of Jig and fixture. (Dec-2016)
12. Analyze the basic principles of jig and fixture design can be categorized (April 2019)

13. Point out the quality function for process plan

14. Infer the factors previously considered for the tooling decision are the most influential on the
calculation of the process parameters.
15. What are the general recommendations for cutting depths for turning and boring

16. What you mean by break-even point?

17. Classify three basic functions of Jigs and fixtures.

PART-B
1. List the information required for process planning (Dec-2016)
2. Describe the set of documents required for Process Planning (Dec-2017,18)
3. What is inspection and write briefly about the different methods of inspection followed in
industries. (Dec-2016)
4. What are the procedure as to be followed for selecting jigs and fixture? Explain briefly (Dec-
2016,April 2018)
5. Explain the importance of selection of the right quality assurance method during manufacturing.
(April 2018)
6. Explain the factors to be considered in selection of process parameters.(April 2018)
7. What are the six basic factors must be considered while selecting measuring instruments.
Explain in detail. (Nov 2018)
8. Write note on economics of process planning?(April 2018)
9. Discuss the following “there are a number of patterns that a process control chart can exhibit that
indicate a process is out of control without any points outside the control limits” (Dec 2018)
10. Show the seven quality control tools and techniques relate to quality improvement and problem
solving?
11. Discuss the main steps in designing a jig/fixture
12. Explain the typical quality characteristics are measured in quality control? Compare the
difference when ‘measuring’ variables and attributes?
13. Explain what is meant by the six degrees of freedom with neat sketch.(Nov 2018)
14. For the part shown in fig ,Calculate the maximum surface speeds for facing ,turning all
surfaces and parting off.The maximum spindle speed of the lathe being used is 600rpm.

UNIT-3

INTRODUCTION TO COST ESTIMATION

PART-A

1. What do you mean by cost estimation ? (Nov/Dec 2016)

2. Define over heat cost? (Nov/Dec 2016)
3. Differentiate costing from estimation. (Apr/May-2017)
4. What are overhead cost? (Apr/May-2017)
5. Distinguish between cost estimation and cost accounting. (Nov/Dec-2017,Nov/Dec-2018)
6. classify the allowances considered in cost estimation(Nov/Dec-2017)
7. Estimate the power cost for melting Aluminium of 150kg at 650c from room temperature of
35c.specific and latent heats of aluminium are 0.91kj/kg and 398kj/kg respectively .unit cost of
power is Rs.7(Apr/May-2018)
8. What are the causes of depreciation? (Apr/May-2018)
9. List out the various methods of allocation of overheads. (Nov/Dec-2018)
10. What is Parametric Estimating? (Apr/May-2019)
11. Why importance of making realistic cost estimates is emphasized? (Apr/May-2019)
12. What are the functions of cost estimation? (Apr/May-2016)
13. What shall be the effect of over estimate? (Apr/May-2016)
14. List the types of Estimates (Nov/Dec-2015)
15. What are the sources for cost estimation? (Nov/Dec-2015)
16. What is conceptual cost estimating? (Nov/Dec-2014)
17. What is target cost? (Nov/Dec-2014)
18. Write any two objectives of cost estimation. (Apr/May-2015)
19. Define Batch costing (Apr/May-2015)

1. (i)(Discuss various methods of costing in details

(ii) Explain the procedure followed for estimating the cost of an individual
Product. (Nov/Dec-2016)
2. (i)Explain any one method of calculating depreciation cost with an example.
(ii) Discuss the various methods used for allocation of overheads. . (Nov/Dec-2016)
3. Explain the different methods of cost estimation. (Apr/May-2017)
4. Describe the various components of the job estimate. (Nov-2017, Nov-2018)
5. Enumerate about conceptual cost estimating method. (Apr/May-2019)
6. Explain the objectives of cost estimating. (Apr/May-2019)
7. Name the various elements of cost. Explain each element in detail
8. Write short notes on cost allowances in estimation
9. Explain the various types of estimation.
10. calculate the selling price per unit from the following data: (Apr/May-2017)
Direct material cost =Rs. 8,000
Direct labour cost=60 percent of direct material cost
Direct Expenses =5percentof direct labour cost
Factory expenses =120percent of direct labour cost
Administrative expenses=80 percent direct labour cost
Sales and distribution expenses=10percent of direct labour cost
Profit=8percent of total cost
No. of pieces produced = 200
11. calculate the selling price per unit from the following data: Direct material cost = Rs. 8,000
Direct labour cost = 60 percent of direct material cost Direct Expenses = 5 percent of direct
labour cost .Factory expenses = 120 percent of direct labour cost Administrative expenses = 80
percent direct labour cost Sales and distribution expenses = 10 percent of direct labour cost
Profit = 8 percent of total cost No. of pieces produced = 200. (Nov-2017, Nov-2018)
12. . A factory has 25 lathes of same make and capacity and 10 CNC machining centres of same
make and capacity .lathe occupies 70m and CNC machining centre occupies 40 m . the factory
expenses are given below:
Description Period Amount is Rs

Building rent and depreciation annual 70,000

Direct labour month 60,000

Indirect labour and indirect material month 50,000

Depreciation charges for lathes annum 2,00,000

Depreciation charges for CNC m/c centre annum 10,00,000

Power consumption for lathe month 3,50,000

Power consumption for CNC m/c centre Month 8,50,000

Insurance for lathes annum 25,000

Insurance for CNC m/c centre annum 20,000

Find out he machine hour for lathe and CNC m/c centre if they work for 5000hrs and 3000hrs
respectively. (Apr/May-2018)

13. An apparel factory has a fork lift truck which is used by receiving and shipping departments, In
receiving section large rolls of fabric are handles while in shipping sections cartons of finished
parts are handled .Fork lift costs are shown in table. Fork lift spends 70% of time in shipping
and 30% in receiving.

Operator salary Rs.75,000

 Maintenance Rs.15,000
Depreciation Rs.20,000
others Rs.5,000

The factory operates two production lines.one line is for jeans and the other for T shirts .operational
dat6a per month is given below
jeans T shirts Total

Units produces 5,50,000 3,20,000 8,70,000

Direct labour hrs 90,000 50,000 1,40,000

Rolls of fabric 2250 850 3100

Cartons shipped 60,000 25,000 85,000

If the total over head of the factory is Rs.18,50,000,Find fork lift expenses per unit of jeans and T
shirts. (Apr/May-2018)

UNIT-4

PRODUCTION COST ESTIMATION

PART-A
Part-A
1. Name the various losses in forging process. (Nov/Dec-2016)
2. Differentiate leftward and rightward welding. (Nov/Dec-2016)
3. Define production cost. (Apr/May-2017)
4. Define Roll forging (Nov/Dec-2017)
5. Name the various material losses in a forging shop. (Apr/May-2017)
6. Give the formula for calculating the cost of power consumed in arc welding (Nov-2017 Nov-
2018)
7. What is right hand and Left hand welding(Apr/May-2018)
8. Name the various sections in a foundry shop. (Nov/Dec-2018)
9. What is meant by Flash loss? (Apr/May-2019)
10. How is cost of material required for casting calculated? (Apr/May-2019)
11. Define Shear Loss
12. Write the forging operations.
13. What are the various elements considered while calculating the cost of welded joint?
14. What costs are associated with manufacturing?
15. List various allowances provided to the pattern.

PART-B
1. State and explain various losses which are to be considered in a Forging shop.
(Nov/Dec-2016, Nov/Dec-2017,Nov/Dec-2018)
2. List the various elements which are to be considered while calculating the cost of a welded
joint. (Nov/Dec-2016)
3. Generalize the meaning of tonghold loss in forging. (Nov/Dec-2016)
4. List the various sections that will be normally found in a foundry shop (Nov/Dec-2017)
5. 200 pieces of a component as shown in Figure are to be drop forged froma bar stock of
diameter 4 cm. Calculate the cost of manufacturing if (1)Material cost is Rs. 1000/meter, (2)
Forging charges are Rs.10 Per cm 2ofsurface area to be forged, (3) On-cost is 10% of material
cost. Consider all possible losses. (Nov/Dec-2016)

6. Calculate (i) the net weight and gross weight for the component shown in Fig. Density of
material used is 7.86 gm/cc and losses= 25% of net weight.

Also Calculate, (ii) Length of 14 mm dia bar required to forge onecomponent. (iii) Cost of
forging/piece if:
Material cost = Rs. 80 per kg; Labour cost = Rs. 5 per piece
Overheads = 150 % of labour cost. (Apr/May-2017)

7. A container open on one side of size 0.5 m x 0.5 m x 1 m is to be fabricated from 6 mm thick
plates Fig. 14 (b). The plate metal weighs 8gm/cc. If the joints are to be welded, make
calculations for the cost of container. (Apr/May-2017)
 The relevant data is;
Cost of plate = Rs.10 per kg
Sheet metal scrap = 5 % of material
Cost of labour = 10 % of sheet metal cost
Cost of welding material = Rs.20 per meter of weld

8. Calculate the welding cost for a cylindrical boiler drum 2.5 m x 1 m diameter which is to be
made from 15 mm thick mild steel plates. Both the ends are closed by arc welding of
circular plates to the drum. Cylindrical portion is welded along the longitudinal seam and
welding is done both in inner and outer sides. Assume the following data: (Nov/Dec-2017,
Nov/Dec-2018)
i. Rate of welding = 2 m per hr on inner side and 2.5 m per hr on outer side
ii. Length of electrodes required = 1.5 m/ meter of weld length
iii. Cost of electrode = Rs. 0.60 per meter
iv. Power consumption = 4 kWh/meter of weld
v. Power charges = Rs.3 /kWh
vi. Labour charges = Rs. 40/hour
vii. Other overheads = 200 percent of prime cost
viii. Discarded electrodes = 5 percent
ix. Fatigue and selling up time = 6 percent of welding time
.
9. A cylindrical boiler drum 3 m x 1 m diameter is to be made from 18mmMS plates. Both
the ends are closed by welding circular plates to the drum. Cylindrical portion is welded
along the longitudinal seam both inside andoutside. Calculate the electric welding cost using
the following data:
Rate of welding is 3 m/hr inside and 4 m/hr outside. Length of electrode required is 1.8 m/m. Cost
of electrode Rs.12/m. Labour charges Rs.100/hr. Discarded electrodes 6% and the setup time is
7% of welding time. Welding Voltage used is 40V and the Current is 325A. Assume the
efficiency of welding transformer as 85%. Power cost is Rs. 7/unit. Overhead charge is 100%
of prime cost. (Apr/May-2018)
10. Find the rate per kg for melting CI in an induction furnace. Furnaceoperates on 3 shift
basics for 300 working days. Assume depreciation period is 10 years and that the furnace
investment is done 100% through bank for an interest rate 12% and the repayment
period is 10 years. (Apr/May-2018)
Furnace cost Rs.60 lakhs.
Power 750 kVA with 0.95 power factor. Power cost is Rs.6/unit
Labour Rs. 20000/month
Material cost Rs. 38 /kg
Miscellaneous and consumable expenses Rs. 70,000 per annum.
Maintenance charge Rs. 2 lakhs/annum
Specific heat of CI = 0.46 kJ/kg and latent heat 272 kJ/kg
Furnace capacity = 1 ton.
11. Calculate the total cost of CI (Cast Iron) cap as shown in Figure from the following data
Cost of molten iron at cupola spout = Rs. 30 per kg, process scrap = 17 percent of net wt. of
casting Process scrap return value = Rs.5 per kg, Administrative overhead charges = Rs.
2 per kg of metal poured. Density of material used = 7.2 grams/cc. The other expenditure
details are:
Process Time per Labour charges per Shop overheads per
 piec hr hr
e
Moulding and pouring 10 min Rs.30 Rs.30
Casting removal, gate 4 min Rs.10 Rs.30
cutting etc.
Felting and inspection 6 min Rs.10 Rs.30
(Nov/Dec-2018)

12. Calculate the cost of forging a crank shaft as shown in Fig. The forging is to be made out of
a bar stock of 50 mm and following data is available: (Apr/May-2019)
i. Material price = Rs. 80 per kg
ii. Direct labour charges = Rs. 23 per piece
iii. Overhead charges = 150 percent of material cost
iv. Density of material = 7.5 gms/cc
v. Losses = 28 percent of net weight.

13. A lap welded joint is to be made as shown in Fig.

(Apr/May-2019)

Estimate the cost of weld from the following data:

Thickness of plate =10 mm
Electrode diameter =6 mm
Minimum arc voltage =30 volts
Current used =250 Amperes
Welding speed =10 meters/hour
Electrode used per meter of weld =0.350 kgs
 Labour rate =Rs. 40 per hr
Power rate =Rs. 3 per kWh
Electrode rate =Rs. 8.00 per kg
Efficiency of welding =50 percent
Connecting ratio =0.4
Overhead charges =80 percent of direct charges
Labour accomplishment factor =60 percent
UNIT-5

(MACHINING TIME CALCULATION)

PART-A
1. Define cutting speed. List various factors affecting cutting speed. (Nov/Dec-2016)
2. What is machining time? (Nov/Dec-2016)
3. Define ‘tool approach’ and ‘tool over travel’ (Apr/May-2017)
4. Define cutting speed. (Apr/May-2017)
5. Write short notes on tear down time. (Nov/Dec-2017, Nov/Dec-2018)
6. Give the formula for calculating machining time for Drilling(Nov/Dec-2017)
7. What are the typical data required for cutting time calculation in shaping (Apr/May-2018)
8. Write steps involved in cutting time calculations (Apr/May-2018)
9. Find the time required to shape a slot 300 mm long, 10 mm wide 5 mm deep in CI block.
Given that cutting speed is 10m/min, feed 1mm/stroke and maximum depth of cut as
2.5 mm. Assume K=0.25. (Nov/Dec-2018)
10. What is meant by interference allowance? (Apr/May-2019)
11. In general, when calculating machining times, allowances are used. Why is it important?
(Apr-2019)
12. List the allowances in machining time.
13. What is tear down time?
14. What is setup time?
15. What are the elements of machining time?

PART-B

1. A mild steel bar 120 mm long and 40 mm in diameter is turned to 38 mm diameter and was
again turned to a diameter of
35 mm over a length of 40
mm as shown in figure.
The bar was chamferedat both
the ends to give a chamfer
o
of 45 x 5 mm after facing.
Calculate the machining time.
Assume cutting speed of 60 m/min and feed 0.4 mm/rev. The depth of cut is not exceed 3
mm in any operation.
(Nov/Dec-2016)
2. (i)Find the time required to drill 4 holes in a CI flange each 2 cm depth, if the hole diameter is
2 cm. Assume cutting speed as 21.9 m/min and feed 0.02 cm/rev. (8 mark)
(ii)A keyway has to be cut in spindle whose dimensions are 46 cm length, 5 cm diameter
and 1 cm width. The cutter diameter is 13.25 cm. If the cutter revolves at 120 rpm, what is the
time required to cut a 1 cm deep key way at a feed of 0.05 cm/rev of cutter? (8mark)
(Nov/Dec-2016)
3. Using the data in Table and the drawing in Fig , determine suitable speeds (rev/min) and
feeds (mm/rev) and the total machining time for all operations listed. The raw material
billet isø85 x 250 mm and the machining allowance to be used is 5 mm. The surface cutting
speeds and feed rate when machining brass using HSS can be selected within the range
50—110 m/min and 0.15—8 mm/rev.
Note: Select the maximum and minimum values within the range for roughing and finishing
operations respectively. (Apr/May-2017)

Operation description Tooling description Cutting condition

Face end HSS turning tool Finish in pass
Turn HSS turning tool One rouging cut, one
Ø80 mm x 160 mm finishing cut of 0.4 mm
Turn HSS turning tool One rouging cut, one
Ø70 mm x 100 mm finishing cut of 0.4 mm
Turn HSS turning tool One rouging cut, one
Ø60 mm x 60 mm finishing cut of 0.4 mm
Parting off HSS parting off tool Finish in pass

4. Calculate the machining time to drill four 8 mm dia holes and one 40 mm dia central hole
in the flange shown in fig. 20 mm dia hole is drilled first and then enlarged to 40 mm hole.
Take cutting speed 10 m/min, feed for 8mm drill 0.1 mm/rev, for 20 mm drill feed is 0.2
mm/rev and for 40 mm drill feed is 0.4 mm/rev. (Apr/May-2017, Nov/Dec-2018)
5. Estimate the time required on a shaper to machine a plate
600 mm × 1,200 mm, if the cutting speed is 15
meters/min. The ratio of return stroke time to cutting
time is 2: 3. The clearance at each end is 25 mm along
the length and 15 mm on width. Two cuts are required,
one roughing cut with cross feed of 2 mm per stroke and
one finishing cut with feed of 1 mm per stroke.
(Nov/Dec-2017)
6. A T-slot is to be cut in a C.I. slab as shown in Figure. Estimate the machining time. Taken
cutting speed 25 m/min, feed is 0.25 mm/rev. Diameter of cutter for channel milling is 80
mm. (Nov/Dec-2017, Nov/Dec-2018)

7. Consider the component as shown in fig.1. The component is to made from mild steel with
carbide tolling at a constant surface speed of 100 m\min on the lathe with a maximum spindle
speed of 1500 rev\min. The machining allowance is 2 mm. Determine: (i) if the lathe is capable
of turning the component at the required surface speed, (ii) the total machining time for the
component if the lathe is capable.
(Nov/Dec-2017)
8. Find the machining time of the components shown in Fig 4. If the material cost is Rs. 55/kg
and the machine hour rate is Rs. 425/hr without OH, find the cost of the component.
Assume over head as 50 % of
machine hour rateand the set up
time is 3 min. Material is AISI
1040. (Apr/May-2018)
9. Calculate the machining time to mill a plate of thickness 24 mm and drill four 10 mm
diameter holes and 50 mm diameter hole in the plate shown in Fig . Assume cutting speed and
feed in the case of milling to be 75 m/min
and 0.2m/min respectively. Cutting
speed for drilling is 30 m/min and feed
0.15 mm/rev for the 10mm drill, 0.18
mm/rev for 25 mm drill and
0.3mm/rev for 50 mm drill.
(Apr/May-2018)

10. Elucidate
about time elements
considered to
arrive at total time
required to
perform a
machining
operation.
(Apr/May-
2019)
11. A mild steel bar 120 mm long and 40 mm in diameter is turned to 38 mm diameter and was
again turned to a diameter of 35 mm over a length of 40 mm as shown in figure. The bar
o
was chamferedat both the ends to give a chamfer of 45 x 5 mm after facing. Calculate
the machining time. Assume cutting speed of 60 m/min and feed 0.4 mm/rev. The depth
of cut is not exceed 3 mm in any operation. (Apr/May-2019)