MADE EASY 2 0 23 WworkbO0K @| Detailed Explanations of a Try Yourself Questions Mechanical Engineering Production Engineering bs GE] MADE EASYBasic Machining Calculations @ Detailed Explanation of Try Yourself Questions Given: D,,, = 100 MM, Day, = 200 MM, Vag = 40 MIMIN, Vinay = 120 mimi Number of gear speed, n = 6 Now because speed are in geometric progression So, a Noni (22x20) 400% 40 Now, let minimum rotational speed is 1, DN Now, v = EOE [where velocity is in m/min and diameter is in mm] Dp * Non 1000 40x1000 _ 200 N, = Niug = Sepgg = g = 88:66 rom Ny 1.481) x (63.66) = 91.10 rpm N, = PN, = (1.481)? x (63.66) = 130.36 rpm N, = PN, = (1.431)° x (63.66) = 186.55 pm N, = rN, = (1.431)¢ x (63.66) = 266.95 pm Ng = ON, = (1.431)8 x (63.66) = 382.00 rpm ow Ny. = Yee X1000 120% 1000 34 67 980 rom tre Dyin x 100 aoan wwwmadeeasypublications.org MADE ERSY © CopyrightShapping and Planning Detalled Explanation 9 of Try Yourself Questions 1 Time taken in one stroke = = min 1 tah one st a0 Total number of stroke = —Wiath__ iateral feed = Total time/out = Width, 1 Feed “60 set = By F oimin a6 “60 © Copyright MADE EASY wowmadeeasypublications orgDrilling Boring and Reaming Detalled Explanation f Try Yourself Questions j000V _ 100020 Speed (N) nD ~ x20 = 318.3 pm x= 20 _<5.7735 mm 2xtan6o" Length to be machined, L + approach + overrun +x = 304243 4x = 35 + 5.7735 = 40.735 mm L __40.7735 Time taken = 75" 53 3185 = 1.28 min wwwmadeeasypublications.org MADE ERSY © CopyrightWidth of slot, b = 20 mm Length of slot, = 100 mm Cutting length Timeout Dern Given’ D = 150mm; Width, b= 1 = 160 mm, Feed, f= v, Length of machining, L Time required for rough machining © Copyright Detalled Explanation of Try Yourself Questions 1000xV _ 1000x60 xD x20 length of slot + approach 20 955 rpm L AN 110 ooiwexoss = 44m 80 mm ; Offset, O,=15 mm ; Number of teeth, z = 10 0.25 mm = 20 mimin 1000V _ 100020 14 I, = 160 + 24 = 184 mm L 184 N ~ 025x10x42.44 ~ 1754 mnute/eut www madeeasypublications.orgNon-conventional Machining Operation Detalled Explanation 9 of Try Yourself Questions ceed 1 _ E%xValency _ 0.18x2 0.62x2 | 0.2x6 = ZexValency _ + - @ ~ Alomeweight ~ 58.93 * 871” 51.99 ~ 081! o = 19876 MAR = Sr el _ 19876500 > Fp ~ 96500 x8.28 MAR = 0.0124 emY/s, T2 : Solution Charging resistance, R = 40 © ; Charging capacitance, C = 20 uF Supply voltage, V, = 220 V ; Charging voltage, V, = 110 V Cycle time = RCIn| “| second V-v - s0x20%10%n| 22 = 0.55 ms Total energy consumed per cycle (or) spark energy = 0.5 CV? = 05 x 20 x 10 x (110 = 0.121 wiCycle Total energy consumed per cycle Average power input = age power inp cycle time = 2121 -ozeKw 0.5510" —_ wwwmadeeasypublications.org MADE ERSY © Copyright® Detailed Explanation 4 J Try Yourself Questions Peery Given: Volume of nuget, V, = 80 mm?, Current, = 10000 A, Energy required for melting of material = 10 J/mm?, Heat lost to surrounding = 500 J Contact resistance, A = 200 uo. Energy required to melt nugget = 80 x 10 = 800 Total energy supplied = 500 + 800 = 1300J 0 Total enorgy supplied, Rt = 1300 . 1300 © (10000)? x 200 10 Time rquired for welding, t = 0.065 second (i) Thermal efficiency of the welding process, 200 = 22 L961 "= 4300 898 n = 61.538% L J e e e Projection welding: 3 spots 000 A, t= 0.015, R= 120 na, d= stributed to the surrounding Hy = H.-Hy © Copyright MADE EASY wowmadeeasypublications org8 Mechanical Engineering © Production Engineeri = (FA)a-(Zar)a = (35000)? x120x 10 x0.093 (ox2.5x10}s = 4410-21195 = 2290.55 Metal depositionrate = dxtxv = 05 x 25x vmmijs 25vx 10" mes mh = 125vx 10°" m¥js x 8000 kgim? = vx 10 kals Vxixn = ril+me,AT 300% 1006 = vx10- {1400x108 +0.5x 10° x(1500-20)} 1800 = v{214} 1600 gat mms 214 q ) { worwmadeeasypublications org MADE ERSY © CopyrightConventional Casting Process Detalled Explanation 9 of Try Yourself Questions ceed For optimum oylindrical side riser, = Volume of casting, V, = 25x 125%5 1562.5 em? Shrinkage of steel during solidification = 3% Minimum volume of the riser necessary is, 0.03 46.875 om? x3 = 140,625 em? v= : : or d= (*) -(222) =5.636cm According to Chvorinov's method, ‘ SA Surface area k = Solidification factor or cylindrical riser = nth = Ee V= mi h= Teh © Copyright MADE EASY wowmadeeasypublications org10 | Mechanical Engineering © Production Engineering MADE EASY Publieatone SA = Oath + One? = Rahs ad? x2 = ath 4 n- xd avon w ke = ndx Vy hate = skal SA = ndx et ao 2-347 Sitferentiating SA (surface area) with respect to d and equating to zero, to get optimum SA, ASA _ VY Bog <9 a) ae 2 e- % x av Ph = ae = d=h for square parallelopiped SA = 21 + 4th’ VePxh if 5 ed —_—T av SA = 2 eax Yai ci 7 Differentiating SA with respect to / and equating to zero, to get optimum SA ASA) a av v (o Ve PRY ro 1 v "axd New (Fnoctne : (i ane SAloaaiccoipednser — BP +4ih’ DP +4lxt 6 comers MADE ERS © copyMADE EASY Detailed Explanations of ry Yourself Questions: ESE +GATE 2023 | 44 Publications As it is given that Volume of cylindrical riser = Volume of parallelopiped riser =x =i As We can write it as vy « (iy SA paraieiopiped riser 6. Now the ratio of time of solidifications ot two optimum riser, fost - (“4 -¢ Feit foratecripes © MIB) ()" 4 (sina seopirie = 1-174 (baatooppediseonims _ The time taken for the solafication of the optimum eyiindrical ser is 1.174 times the time taken for the solidification of the optimum patallelopiped riser. Given: Aluminium cube side, a = 10 cm, For cylindrical riser, h = d, Volume shrinkage = 6% {i) Shrinkage volume of cube on solidification = 6% of cube volume 6xa _ 6x10 “oo ~ 1000"? i) Riser volume, V, = 3 x (shrinkage volume) 3 x (0.06 x 10%) < 180 cm? Publlaations a cna © Copyright MADE EASY wonmadeeesypublatonsorg)12 Mechanical Engineering * Production Engineering MADE EASY Publieatone = 21? _ sop 2. teow (> @) We know that, ah? a) Which is not true for the given riser design (= () So redesigning the riser. A? lal d 2 e 1667 d2 10cm So, minimum diameter of riser, d = 10 em Minimum height of riser, h = d = 10 em Volume of riser, V x oth = Fat ane 785.40 cm? www.madeeasypublications.org MADE EASH ca