Assignment

Manufacturing Processes (5th Sem, Mechanical Engineering)

Submission last date: - 15th June 2023.

1. What are the different “Gating systems” in the casting process? Briefly explain
the significance of both “Top Gate” and “Bottom Gate” casting.
2. Explain the phenomenon of “Arc Blow” in the welding process.
3. Name different independent variables and three dependent variables in metal
cutting.
4. What is the significance of the rake angle in the metal cutting process?
5. During the orthogonal cutting of mild steel with a 10° rake angle tool, the chip
thickness ratio was obtained as 0.4. The shear angle (in degrees) evaluated
from this data is……………………..
6. The rake angle of a cutting tool is 15°, the shear angle 45°, and the cutting
velocity 35 m/min. What is the velocity of the chip along the tool face?
7. Under certain cutting conditions, doubling the cutting speed reduces the tool
life to 1/16th of the original. Taylor’s tool life index (n) for this tool-workpiece
combination will be………………
8. In a rolling operation using rolls of diameter 500 mm, if a 25 mm thick plate
cannot be reduced to less than 20 mm in one pass, the coefficient of friction
between the roll and the plate is…….
9. The thickness of a metallic sheet is reduced from an initial value of 16 mm to
a final value of 10 mm in one single pass rolling with a pair of cylindrical
rollers each of a diameter of 400 mm. The bite angle in degree will
be…………………………
10. Explain the significance of “Flash” and “Gutter” in the forging process.
11. Explain in detail the difference between “Cold working” and “Hot Working”
12. Mild steel is being machined at a cutting speed of 200 m/min with a tool rake
angle of 10. The width of the cut and uncut thickness are 2 mm and 0.2 mm
respectively. If the average value of the coefficient of friction between the tool
and the chip is 0.5 and the shear stress of the work material is 400 N/mm2,
Determine:-
(i) shear angle and
(ii) Cutting and thrust component of the force.

Hint: - Use merchant analysis for calculating the shear angle and merchant circle diagram for
calculating forces.