BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI

MF F243: MANUFACTURING PROCESSES

Comprehensive Examination – Open Book
Max Marks: 80 Duration: 120 min. Date: 4th Jan, 2021

Note: Justify the answer of each question. Marks will not be awarded without justification. No partial marking
for theoretical questions

Q1. An XYZ industry wants to manufacture 1000 products with maximum precision of shape as shown in figure from
a raw material (Cast Iron) of size 100 × 100 × 50 mm3 with maximum productivity on a conventional machine
tool. The length of the slot shown in figure is 80 mm. The available machine tools and cutting tools in the company
are following and the details are mentioned in Table. [20]
Machine Tool: Shaper, Drilling, Vertical Milling Machine
Cutting Tool: Drill bits, Right hand single point cutting tool, Plain milling cutter of diameter 5 mm with 20 teeth,
Plain milling cutter of diameter 15 mm with 2 teeth, Face milling cutter of diameter 30 mm with 12 teeth, End
milling cutter of diameter 5 mm with 3 teeth.
i) What sequence of operation (s) you will select to manufacture the product? Justify [4]
ii) Is the selected operation (s) orthogonal or oblique? Justify [4]
iii) Determine the minimum machining time to manufacture the component. [8]
iv) If the industry operates 8 hours a day and 300 days in a year, how many components it will produce in one year?
Working Parameters Drilling Boring Shaper Milling 5
Cutting Tool four flute drill Boring Single point Milling
bits of dia. 5, bar cutting tool cutters
15, 27, 36, mm
15
Feed (mm/tooth) 0.12 0.5 0.15 0.10
mm/stroke mm/tooth 50

Return stroke to - - 1.20 -

Cutting stroke All dimensions are
in ‘mm’
velocity ratio
Max. Depth of cut 8 1 5 5 100
(mm)
Cutting Speed (m/min) 42 - 20 35
Stroke length - - 150 -
Point angle 1400 - - -
Helix angle 250 - - -
Clearance at each end - - 20 -
Length of approach 3 2 3 2
(mm)
Length of over-travel 2 3 2 3
(mm)
Side Cutting Edge - 450 450 450
Angle
rpm 275, 435, 685, 435 - 400, 800,
1082 1600

Q2.
i) What values of progression ratio you will recommend for a large size grinding machine tool? Justify your answer
analytically. [10]
ii) Enlist the various major states showing graphically during which energy is consumed by a conventional
grinding machine tool. Justify the selection of states. [5]
iii) Why conventional machine tools like grinding are provided with large number of spindle speeds? [5]

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Q3.
A work piece shown in figure below is to be made from the casting process. [10]

i) Show the direction of solidification (using arrows) inside casting. Justify your direction
ii) In which portion of the workpiece shrinkage cavity are likely to be formed, if riser is not provided. Justify
your answer.
iii) Do you think the above work piece needs a riser? If yes, then suggest a suitable position for placing the
riser. If no, why it is not required? Justify your answer.
Q4. [6 X 5 = 30]
i) Suggest the application where you will recommend the zero degree back rake angle. Justify
ii) In a four high roll mill, why we use small rolls as working rolls and the large rolls as backup rolls?
iii) An industry want to set up a plant to manufacture the rail lines for mass production. Which manufacturing
process you will recommend? Justify your recommendation.
iv) Which angle in drill bit is equivalent to rake angle in single point cutting tool? Justify
v) Which manufacturing process you will recommend to manufacture the crankshafts? Justify
vi) An industry want to set up a plant to manufacture a product having projections and undercuts by casting. Which
type of pattern you will recommend for higher productivity and accuracy? Justify your recommendation.

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