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Question Paper Code : 40844

B.E./B.Tech. DEGREE EXAMINATIONS, NOVEMBER/DECEMBER 2021.

Seventh/Eighth/Ninth Semester

Manufacturing Engineering

ME 8793 — PROCESS PLANNING AND COST ESTIMATION

(Common to Material Science and Engineering/Mechanical Engineering/Mechanical

Engineering (Sandwich)/ Mechanical and Automation Engineering/Mechatronics
Engineering/Production Engineering/Robotics and Automation)

(Regulations 2017)

Time : Three hours Maximum : 100 marks

Answer ALL questions.

PART A — (10  2 = 20 marks)

1. Mention the factor affecting process planning.

2. What are parameters to determine the tool performance?

3. What are the functions of jig and fixture?

4. List the use of quality assurance.

5. Define overhead cost.

6. Distinguish cost estimation and cost accounting.

7. List the losses occur that during forging.

8. What is shrinkage allowance?

9. What is tear down time?

10. Mild steel shaft 20 cm long is to be ground rough from 33.3 to 33 mm dia using
grinding wheel of 40 mm face width with the work speed of 12m/min and depth
of cut 0.02 mm per pass, and 115 rpm. Calculate the time taken to grind the
job.

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PART B — (5 × 13 = 65 marks)

11. (a) Enlist the common approaches in CAPP system and state their
advantages and limitations.

Or

(b) Explain basic steps involve in process planning.

12. (a) What are the factors to be considered in the selection jigs and fixtures?

Or

(b) Explain the various quality assurance methods in detail.

13. (a) From the following data provided by a mask machine manufacturer, find
prime cost, factory cost, production cost, total coat and profit.
Items INR
Value of stock material as on 1-07-2021 52,000
Material purchased 5,48,000
Wages to workers 2,40,000
Depreciation of plant and machinery 16,000
Depreciation of office equipment 4,000
Rent, taxes and insurance 32,000
General administrative expenses 6,800
Water, power and telephone bill of factory 19,200
Water, power and telephone bill of office 5,000
Transportation in factory 4,000
Insurance and rent of office building 4,000
Direct expenses 1,00,000
Commission and pay of salesman 21,000
Repair and maintenance 2,000
Production Managers salary 60,000
Salary of office staff 1,20,000
Value of stock of material on 30-06-2021 72,000
Sale of products 12,72,000

Or

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(b) Find out the production cost per gear for a transmission unit in
automobile from the following data.
Charges for forging per kg Rs. 22.5
Wrought iron used per month @ Rs. 90 per Kg 27 tonnes
Wages of operator Rs. 450/day
No of operator employed 36
Cartage/day Rs. 2,250
Deprecation of machines and tools Rs. 4500 per month
Wages of helpers Rs. 270 per day each
No of helpers employed 8
Salary of supervisor Rs. 45,000 per month
Packing charges for 108 gears Rs. 360
Electric charges Rs. 11700 Per month
Salary of manager and maintenance staff Rs. 1,26,000 per month

If 13,500 gears are to be produced per month and factory runs 26 days a
month at 8 hour shift then what should be the selling price of each gears
so as to earn profit of 20 percentage of factory cost?

14. (a) Calculate the cost of forging a crank shaft as show in figure 1 below using
the following data available. The forging is to be made out of 50 mm dia.
Material price Rs.100 per kg
Direct labour charges Rs. 43 per piece
Overhead charges 150% of material cost
Density 7.5 g/cc
Losses 28% of net weight

Figure 1

Or

3 40844

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(b) Calculate the cost of welding two pieces of mild steel sheets each
2 meters long and 7 mm thick. A 60° V is prepared by means of gas
cutting before welding is to be commenced. The cost of oxygen is Rs. 7/cu
meter and acetylene is Rs. 4/cu meter. The filler metal costs Rs. 20
per kg.

The following data is also available :

For gas cutting (10 mm thick plate)

Cutting speed 20 m/hr

Consumption of oxygen 2 cu m/hr

Consumption of acetylene 0.2 cu m/hr

Data for rightward welding

Consumption of oxygen 0.8 cu m/hr

Consumption of acetylene 0.8 cu m/hr

Dia of filler rod used 3.5 mm

Filler rod used per meter of weld 3.4 m

Rate of welding 3 m/hr

Density of filler metal 8 g/cc

15. (a) A 400 mm  60 mm rectangular cast iron piece is to be face milled with a
carbide cutter. The cutting speed and feed are 60 m/min and
60 m/mm. If the cutter diais 80 mm with 12 cutting teeth. Find cutter
r.p.m. feed per tooth, milling time.

Or

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(b) Calculate the machining time to drill eight 8 mm dia holes and one
40 mm dia central hole in the flange shown below (Figure 2). With
cutting speed 10 m/min, feed for 8 mm drill 0.1 mm/rev, 40 mm drill is
0.4 mm/rev, 20 mm dia drill 0.2 mm/rev.

Figure 2

PART C — (1 × 15 = 15 marks)

16. (a) A mild steel bar 150 mm long and 48 mm in diameter is turned to 45 dia
and was again turned to diameter of 42 mm over a length of 60 mm as
shown in Figure 3 below. The bar was machined at the both the ends to
give the chamber of 45  5 mm after facing. Calculate the overall
machining time, take cutting speed of 60 m/min and feed 0.4 mm/rev. The
depth of cut should not exceed 3 mm.

Figure 3

Or

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(b) A cast iron component is to be manufactured as shown in Figure below.

Estimate the selling price per piece from the following data:
Density of material 7.2 gms/cc
Cost of molten metal at cupola spout Rs. 20 per kg
Process scrap 20 percent of net weight
Scrap return value Rs. 6 per kg
Administrative overheads Rs. 30 per hour
Sales overheads 20 percent of factory cost
Profit 20 percent of factory cost
The component shown in figure 4 is obtained after machining the casting.
The pattern which costs Rs. 5,000 can produce 1,000 pieces before being
scrapped. The machining allowance is to be taken as 2 mm on each side.

Figure 4

————————

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*X10713* Reg. No. :

Question Paper Code : X10713

B.E./B.Tech. Degree Examinations, November/december 2020

and April/May 2021
Seventh/Eighth Semester
Mechanical Engineering
ME 8793 – Process Planning and cost estimation
(common to materials science and Engineering, mechatronics Engineering,
mechanical and automation Engineering, and Robotics and automation
/production Engineering/manufacturing Engineering)
(Regulation 2017)

Time : Three Hours Maximum : 100 Marks

Answer all questions.

paRT – a (10×2=20 Marks)

1. Write short notes on collective-single part drawing.

2. Differentiate between continuous cutting and intermittent cutting with an

example.

3. In a turning process, the length of work piece is 80 mm, feed is 0.5 mm/rev.
and cutting speed is 500 rpm. Calculate the time required for the cutting
operation.

4. In a manufacturing industry, the fixed cost for a particular year is Rs. 2,50,000.
The variable cost is Rs. 15 per unit. The selling price of the component is
Rs. 40. Calculate the value of break-even quantity.

5. Brief on cost accounting.

6. What do you mean by depreciation ?

7. In hot working process, surface finish is not good. Justify this statement.

8. List out few examples for indirect material cost in casting.

9. Define approach length in turning process.

10. Which operation is done to provide gripping in metal handles ?

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X10713 -2- *X10713*

paRT – B (5×13=65 Marks)
11. a) Explain in detail about the retrieval type CAPP system.
(OR)
b) Enlist the technical factors to be considered for machine selection
and explain them in short.

12. a) Discuss about the principles of jigs and fixtures design.

(OR)
b) List out the set of documents required for process planning.

13. a) Briefly explain the various elements of cost.

(OR)
b) Classify and explain the allowances used in calculating the standard
time.

14. a) It is required to make a lap joint in a 11 mm M.S. plate using flat welding
position with 8 mm electrode as shown in figure. Welding speed is 10 meters
per hour. When 0.4 kg of metal is deposited per meter length of joint for
the current used with 250 amperes and voltage is 30 volts. Labour cost
is Rs. 50 per hour, power rate is Rs. 8 per KWhr and cost of electrode is
Rs. 60 per kg. Efficiency of the machine is 50% and operating factor is 60%.
Calculate the cost of labour, power and electrode per meter of welding.

(OR)
b) 200 components have to be manufactured as shown in the figure, by
upsetting process from a 30 mm diameter bar. Calculate the net weight,
gross weight and length of 30 mm bar required. Consider the total losses
of the process as 12%. The density of the material is 7.86 gm/cc.

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*X10713* -3- X10713

15. a) Calculate the total time required to turn one component shown in figure
from a 50 mm diameter raw material, using a spindle speed of 800 rpm,
feed 0.4 mm/rev. and depth of cut 2.5 mm/pass for the whole operation.

(OR)
b) Calculate the time required for shaping a C.I. block of 500 × 200mm. The
cutting speed of shaper is 15 m/min with a feed of 0.9 mm/stroke. The
clearance on each side is 20 mm along the length and 15 mm along the
width. The ratio of return stroke to cutting stroke is speed is 3:2.

paRT – C (1×15=15 Marks)

16. a) A bolt can be produced either by capstan late or CNC lathe. In capstan
lathe, time taken is 1 hour and overhead cost is 50% of labour cost. In CNC
lathe time taken is 5 hours for 100 products and overhead cost is 120% of
labour cost. The material cost of each product is Rs. 60 and labour cost is
Rs. 50/hour in both machines. Which of these two machines is economical
for making the bolt ?
(OR)
b) List out the various operations involved in the manufacturing of the part
shown in figure from a mild steel raw material of 60 mm diameter and
130 mm length. Make a process planning sheet and indicate the machines
and cutting tools required for the same. Tolerance is ± 0.1 mm unless
specified.

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