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GUJARAT TECHNOLOGICAL UNIVERSITY

AUTOMOBILE ENGINEERING (02)

/MECHANICAL ENGINEERING (19) MANUFACTURING PROCESSES – I

SUBJECT CODE: 2131903

B.E. 3RD

SEMESTER

Type of Course: Engineering

Prerequisite: Zeal to learn the subject

Rationale: Manufacturing processes related to machining are included in this subject. All conventional

machines are included in this course to understand the basic concepts in machining science.

Teaching and Examination Scheme:

Teaching Scheme Credits Examination Marks Total

Marks L T P C Theory Marks Practical Marks

ESE

(E)

PA (M) PA (V) PA

(I) PA ALA ESE OEP

3 0 2 5 70 20 10 20 10 20 150

Content:

Sr.

No.

Topics Teaching

Hrs.

Module

Weightage

1. Basic Machine Tools and Metal Cutting Principles:

Machine tools classification, working and auxiliary motions in

machine tools, Primary cutting motions in machines tools, Cutting

tool geometry and tool signature, cutting forces and power

requirement in machining

4 8%

2. Metal Cutting Lathes:

Engine Lathes, construction all arrangement and principal units of

engine lathes, type and size range of engine lathes, Operations

carried on engine lathe , attachment extending the processing

capacities of engine lathes, Types of lathe machines, Capstan and

Turret lathes, Taper turning on lathe, Thread cutting on lathe using

gear train and chasing dial, Alignment tests of lathes.

11 22%

3 Drilling Machines:

Purpose and field of application of drilling machines, Types of

drilling machines, Drilling and allied operation: drilling, boring,

reaming, tapping, counter sinking, counter boring, spot facing; deep

hole drilling, alignment tests of drilling machine.

6 12%

4. Boring Machine:

Purpose and filed of application, Horizontal boring machines,

Precision boring machines.

3 6%

5. Milling Machines:

Purpose and types of milling machines, general purpose milling

machines, different types of milling operations, milling cutters,

attachments extending the processing capabilities of general

11 22%

purpose milling machines, Indexing, Helical milling operation and

its set up, Alignment tests of milling machine.

6. Planers, Shapers and Slotters:

Classification of milling machine, Attachments extending the

processing capacities of milling machine, machine and tooling

requirements

6 12%

7. Sawing and Broaching Machines:

Metal sawing classification: reciprocating sawing machines,

circular sawing machines, band sawing machines, Types of

broaching machines, advantage and limitations of broaching.

3 6%

8. Grinding Machines and Abrasives:

Classification of grinding machines, cylindrical grinders, internal

grinders, Surface grinders, tool and cutter grinders, center less

grinders, Types of grinding wheels, wheel characteristics and wheel

selection.

6 12%

Reference Books:

1. Workshop Technology Vol. I, II & III, WAJ Chapman.

2. Workshop Technology Vol. II, Hajra & Choudhari.

3. Manufacturing Processes, O.P. Khanna.

4. Production Technology, R. K. Jain.

5. Processes and Materials of Manufacture; Lindberg Roy A.; Prentice-Hall India.

6. Principles of Manufacturing Materials and Process, J S Campbell.

Course Outcomes:

At the end of this course students will be able to:

1. Understand the basic concept of machining operations.

2. Analyze any conventional machining processes.

3. Generate the sequence of machining operation to produce the end product.

4. Judge the limitations and scope of machines to perform variety of operations.

List of Practical:

1. Study of Machine Tools (Lathe, Shaper, Slotter, Planner) – study the types of cutting tools available

and relative motions between cutting tool and work piece on each machine tool. Also derive capacity

and capability of respective machine tools from machine specifications and number of available

attachments to perform variety of operations.

2. Study of Machine Tools (Grinding, Milling, Drilling) – study the types of cutting tools available and

relative motions between cutting tool and work piece on each machine tool. Also derive capacity and

capability of respective machine tools from machine specifications and number of available

attachments to perform variety of operations.

3. Job making on lathe machine

4. Job making on shaper / slotter machine

5. Job making on milling machine

6. Job making on Drilling machine

7. Job making on Grinding machine

8. Alignment test on lathe machine / any other machine

Students will be performing the actual machining operation on respective machines in groups or

individually with the help or guidance of Lab technician.

Open Ended Problem:

1. Develop a simplest possible Tool Dynamometer to determine the force the tool exerts on the work

piece in a lathe.

2. Develop a machine to make holes in very soft material.

3. A precise hole is to be drilled in a rod of circular cross section at a specified distance from the end of

the rod. Thousands of such parts are required. Develop a jig or fixture to ensure that all the pieces are

identical.

4. Develop a machine to make corrugated metal sheet.

5. Gold of very thin gage is to be used to cover the body of a Rolls Royce car. Design a process/machine

to make such a thin gage and demonstrate using any easily available material

6. Students may be asked to provide a design set up for machining any component / product on any of

the conventional machine studied in this course. Moreover, a detailed sketch of each of the operations

in a proper sequence on a specific machine or different machine may also be derived by student to

conclude an appropriate design.

Major Equipments:

All conventional machine tools such lathe, milling, shaper, slotter, drilling machine, grinder, etc.

ACTIVE LEARNING ASSIGNMENTS: Preparation of power-point slides, which include videos,

animations, pictures, graphics for better understanding theory and practical work – The faculty will

allocate chapters/ parts of chapters to groups of students so that the entire syllabus to be covered. The

power-point slides should be put up on the web-site of the College/ Institute, along with the names of the

students of the group, the name of the faculty, Department and College on the first slide. The best three

works should submit to GTU.

1

Seat No.: ________ Enrolment No.___________

GUJARAT TECHNOLOGICAL UNIVERSITY BE - SEMESTER–III (NEW) - EXAMINATION – SUMMER 2017

Subject Code: 2131903 Date: 31/05/2017 Subject Name: Manufacturing Process-1 Time: 10:30 AM to 01:00 PM Total Marks: 70 Instructions:

1. Attempt all questions. 2. Make suitable assumptions wherever necessary. 3. Figures to the right indicate full marks.

MARKS

Q.1 Answer following short questions 14

1 What is “chip thickness ratio”?

2 Define the term ‘machining’.

3 What do you mean by term ‘taper’?

4 Define term ‘cutting speed’ as applied to a lathe machine.

5 What do you mean by grinding process?

6 What do you mean by ‘depth of cut’ applied to drilling operation?

7 Define term ‘feed’ as applied to a milling machine.

8 Define term ‘MRR’ (material removal rate).

9 What is ‘counter boring’?

10 What do you mean by indexing?

11 Why boring operation is required after drilling operation?

12 What is grinding wheel?

13 Define gang milling operation.

14 Why nose radius is provided in single point cutting tool?

Q.2 (a) List various work holding devices and attachments use in milling

machine. 03

(b) Give the comparison between a turret lathe and capstan lathe. 04

(c) Explain various types of chucks used on lathe machine. 07

OR

(c) Write advantages, limitations and applications of “Broaching-

Machines “. 07

Q.3 (a) List the common operations which can be carried out on lathe. 03

(b) State the conditions under which use of positive and negative rake

angles are recommended. 04

(c) With the help of figure explain ‘Crank and slotted link quick

return Mechanism. 07

OR

Q.3 (a) Give classification of milling machine. 03

(b) Draw a line sketch diagram of lathe machine and indicate

principle parts on it. 04

(c) Enlist various Milling Operations. Discuss the following operations.

1. Straddle Milling 2. Gear Milling 3. Face Milling 07

Q.4 (a) What is the principle of working of shaper? 03

(b) Explain types of motions in machine tools with examples. 04

(c) List various taper turning methods use in lathe machine and

explain taper turning by setting over the tail stock. 07

OR

Q.4 (a) Write specifications of radial drilling machines. 03

(b) State difference between up milling and down milling. 04

2

(c) Classify drills. Explain nomenclature of twist drill with neat sketch. 07

Q.5 (a) Explain the following terms.

i) Glazing ii) Loading iii) Dressing 03

(b) State difference between planner and shaper. 04

(c) List various types of planers. Compare in detail Shaper and planer. 07

OR

Q.5 (a) Give classification of machining process. 03

(b) What are the advantages of grinding process over other cutting

processes? 04

(c) With the help of figure explain ‘Hydraulic shaper mechanism. 07

*************

1


GUJARAT TECHNOLOGICAL UNIVERSITY BE - SEMESTER–III(New) • EXAMINATION – WINTER 2016

Subject Code:2131903 Date:02/01/2017

Subject Name:Manufacturing Process-1

Time: 10:30 AM to 01:00 PM Total Marks: 70 Instructions:


MARKS

Q.1 Short Questions 14

1 Differentiate between primary and auxiliary cutting motions in

machine tools.

2 What is the function of a follower rest during turning? 3 State when up milling is preferred to down milling. 4 What is the function of a dead centre? 5 What is the importance of a helix angle in a drill bit? 6 Name the types of abrasives used for making a grinding wheel. 7 Write Taylor’s tool life equation. 8 Define tool life. 9 State the function of cutting fluids. 10 What are natural and artificial abrasives? 11 What is a clapper box in a shaper? 12 Define “feed” in a turning operation. 13 Define ‘boring’. 14 How many tools can be fitted on a capstan lathe at a time?

Q.2 (a) Explain the difference between right hand and left hand single point

cutting tools with neat sketches.

03

(b) Explain the importance of back rake and end relief angles in a single

point cutting tool

04

(c) State the advantages of all geared head stock as against a belt

driven headstock. Explain the function of a half nut during lathe

operation with a neat sketch.

07

OR

(c) Name the accessories commonly used to enhance the lathe

operation. Explain the function of different types of mandrels.

07

Q.3 (a) What is the material of a lathe bed? Why? 03

(b) Compare the benefits and limitations of a three jaw chuck vis-à-vis a

four jaw chuck.

04

(c) Name the drilling operations. Explain counter boring and spot facing

with neat sketches.

07

OR

2

Q.3 (a) Calculate the change gears to cut a single start thread of 0.5 mm

pitch on a centre lathe having a lead screw of 1 mm pitch.

03

(b) Explain the specifications of a drilling machine. 04

(c) With a block diagram, describe the main features of a horizontal

boring machine.

07

Q.4 (a) Explain reaming and tapping with neat sketches. 03

(b) Explain gang milling and straddle milling with neat sketches. 04

(c) Give neat sketches of internal pull type broach and indicate the

various terms relative to its teeth.

07

OR

Q.4 (a) Explain the importance of conducting alignment tests on a machine

tool.

03

(b) Name the alignment tests required to be carried out on a milling

machine.

04

(c) Explain simple indexing and compound indexing in milling

operations.

07

Q.5 (a) Differentiate between up milling and down milling. 03

(b) Differentiate between shaper and planer. 04

(c) State the factors to be considered for the selection of a grinding

wheel. Explain the importance of wheel diameter.

07

OR

Q.5 (a) Explain the specifications of a shaper. 03

(b) Explain how worktable reversal is obtained in a shaper. 04

(c) Explain the specifications of a grinding wheel. Explain why a hard

wheel is recommended for grinding a soft material and vice versa.

07

*************

1



BE - SEMESTER–III(New) EXAMINATION – SUMMER 2016


Subject Name:Manufacturing Process-1 Time:10:30 AM to 01:00 PM Total Marks: 70 Instructions:

1. Attempt all questions.

2. Make suitable assumptions wherever necessary. 3. Figures to the right indicate full marks.

MARKS


1 Define lip angle.

2 Identify the following tool signature 8-12-6-6-6-10-1 in ASA system.

3 Define Tool life.

4 Explain Steady rest and Follower rest.

5 What is the function of Face Plate?

6 Define the following terms:

(i) Reaming (ii) Counter-boring

7 List out various operations which can be performed on Shaper machine.

8 With the help of sketch only indicate drive motion and feed motion for

shaper and planer m/c.

9 Write different applications of broaching.

10 Explain primary cutting motion for lathe machine with neat sketch.

11 Explain the meaning of grinding wheel signature: 26-C-60-M-7-V-28.

12 State the limitations of the taper turning attachment in lathe.

13 Define the function of Feed rod and lead screw.

14 Explain the requirement of Angle plate in lathe machine.

Q.2 (a) List the alignment tests to be carried out on the milling machine. 03

(b) Explain the classification of machine tools. 04

(c) Explain twist drill nomenclature with neat sketch. 07

OR

(c) List out various operations carried out on drilling machine. Explain any

four. 07

Q.3 (a) Explain basic elements of machining. 03

(b) Explain various factors which are affecting tool life. 04

(c) Explain primary and auxiliary motions with reference to machine tool. 07

OR

Q.3 (a) Explain single point cutting tool geometry. 03

(b) Compare orthogonal and oblique cutting. 04

(c) Define a Basic Machine Tool. Classify them What are the general

requirements of machine tools?

07

Q.4 (a) Calculate the tailstock set-over for turning a taper on a job whose

diameters are 80 mm and 60 mm. The length of the job is 350 mm and

the length of the tapered portion is 250 mm.

03

(b) Write a short note on: “Apron mechanism” 04

2

(c) Discuss with sketch characteristics of conventional Up and Climb milling. 07 OR

Q.4 (a) Determine the cutting speed in machining a workpiece of 200 mm

diameter rotating at a speed of 100 rpm. Also calculate machining time if

workpiece length is 0.5 m and feed is 0.45 mm/rev.

03

(b) Give the differences between gang drilling and multiple drilling

machine. 04

(c) How grinding wheel is specified? Explain in details. 07

Q.5 (a) Give merits and demerits of Planer. 03

(b) Explain jig boring machine 04

(c) What is Tool Signature and Tool Geometry? Explain importance of tool

angles for single point cutting tool in brief 07

OR

Q.5 (a) Explain the effect of unequal lips in twist drill. 03

(b) List out various milling machine operations and explain any two. 04

(c) Explain crank and slotted link quick return mechanism in shaper. 07

*************

1


GUJARAT TECHNOLOGICAL UNIVERSITY BE - SEMESTER–III (New) EXAMINATION – WINTER 2015


Subject Name: Manufacturing Processes - I

Time: 02:30pm to 05:00pm Total Marks: 70 Instructions:


2. Make suitable assumptions wherever necessary.

3. Figures to the right indicate full marks.

MARKS


1 Define feed in the turning operation

2 What is provided in place of tailstock in Capstan lathe?

3 Why is quick return mechanism used in shaping machine?

4 Give names of any two types of milling cutters.

5 What is the function of steady rest?

6 What is dead centre?

7 For which operation is the lead screw used?

8 What is the function of reamer?

9 What is a face plate?

10 What is function of a Mandrel?

11 Explain why broaching cannot be used to machine a blind hole.

12 In planner, does tool reciprocate or work piece reciprocates? tool signature 8-14-6-6-20-15-4.

13 In tool signature 8-14-6-6-20-15-4, what is nose radius value?

14 What is the material of bed in conventional machine tool?

Q.2 (a) Give classification of grinding machine. 03

(b) Define a Basic Machine Tool and state the general requirements of

machine tools? 04

(c) Draw neat sketch of column & knee type milling machine. Label

the main parts. State functions of each part. 07

OR

(c) With neat sketch explain how stroke length can be set on a shaper

having crank and slotted link mechanism? 07

Q.3 (a) Can slotter be called as vertical shaper? Justify your answer. 03

(b) Describe working of circular sawing machine with neat sketch. 04

(c) List the methods of taper turning on lathe machine. Explain with

neat sketch the taper turning method that can be used for taper

turning long length job.

07

OR

Q.3 (a) Explain how grinding wheels are classified. 03

(b) Explain working of surface grinding machines. 04

(c) Explain the thread cutting operation on lathe machine. 07

Q.4 (a) Derive the formula to estimate the machine time calculation for

turning operation 03

2

(b) Why different spindle speeds are provided on an engine Lathe?

Explain 04

(c) Draw a neat sketch with label of following operation and indicate

direction of cutting parameters on it. i) Reaming ii) boring iii)

Counter boring iv) Countersinking v) Spot facing vi) Tapping vii)

Trepanning.

07

OR

Q.4 (a) Explain the following terms.

i) Glazing ii) Loading iii) Dressing 03

(b) Explain Up milling with help of neat sketch, 04

(c) Explain gang drilling machine with a neat sketch. How does it

differ from multiple spindle machine? 07

Q.5 (a) Explain Centerless grinding process to grind inside hollow pipes. 03

(b) Derive equation for calculating the taper angle by compound

slide method on Lathe operation.

04

(c) Why alignment test are required on machine tool? With a neat

sketch explain any two alignment test. 07

OR

Q.5 (a) Differentiate between centre type and centre less grinding

machines.

03

(b) With help of neat sketch explain vertical boring machine 04

(c) Explain simple indexing and compound indexing for a milling

machine

07

*************

1


GUJARAT TECHNOLOGICAL UNIVERSITY BE - SEMESTER– III EXAMINATION – SUMMER 2015

Subject Code: 2131903 Date:29/05/2015

Subject Name: MANUFACTURING PROCESSES-I

Time: 02.30pm-05.00pm Total Marks: 70 Instructions:




Q.1 (a) List the surface finishing processes. Why can close dimensional tolerances be

not guaranteed with surface finishing operations?

07

(b) State the purpose of each part on lathe:

(1) Face Plate, (2) Lead screw,(3)Steady rest, (4) Chasing dial, (5) Mandrel,

(6) Split nut and (7) Tail stock.

07

Q.2 (a) With help of neat diagram explain the following setup on centre lathe:

(1) Use of fixed steady for drilling on end of a long bar.

(2) A knurling operation set up.

(3) Taper turning by swiveling compound rest.

07

(b) List the work holding devices used for holding work on a drilling machine and

explain with neat sketch any three.

07

OR

(b) Determine the time required to drill a hole of 25mm diameter in a cast iron

work piece 50mm thick using a high speed steel drill. The cutting speed and

feed rate for the operation may be assumed to be 0.50 m/s and 0.5 mm/rev

respectively. The drill point angle is 118˚m. An approach and over travel may

be assumed to be 8mm.

07

Q.3 (a) With help of neat sketch explain vertical boring machine and state function of

its parts.

07

(b) List different type of reamers commonly used on drilling machine and

describes with neat sketch any three.

07

OR

Q.3 (a) What do you understand by (1) Gang milling (2) Straddle milling (3) String

milling?

07

(b) Explain method of mounting and application of the following cutters used on

milling machine: (1) End mills, (2) Slitting saws and (3) Slab milling cutter.

07

Q.4 (a) Explain with neat sketch shaper feed mechanism. 07

(b) Draw a neat sketch of slotter and explain function of principle parts of slotter. 07

OR

Q.4 (a) Calculate machining time for steel slab top surface 400mm wide and 500mm

long to be planed on a planer. The cutting speed and return speed are 20

m/min and 80 m/min respectively. Take machining allowance as 10mm , side

over travel of tool as 3mm,table over travel on both side as 100mm and tool

approach angle as 45˚.The cross feed of tool is 3mm/full stroke.

07

(b) Explain basic principle of broaching. Make neat sketch of internal pull type

broach showing various terms related to its teeth and explain significance of

these terms.

07

Q.5 (a) What is meant by setting the saw teeth? Describe various types of teeth sets

and give their application.

07

2

(b) Discuss with neat sketch how are the following alignment test conducted on

lath :( 1) Spindle Centre run out (2) Pitch accuracy of lead screw.

07

OR

Q.5 (a) List the various types of bond used in manufacture of grinding wheels. State

the type of application in which each bond is useful.

07

(b) Explain how you will check the following on milling machine:

(1)Central T-slot square with arbor (2) Work table parallel with arbor rising

towards over arm.

07

*************

1


GUJARAT TECHNOLOGICAL UNIVERSITY BE - SEMESTER–III • EXAMINATION – WINTER • 2014

Subject Code: 2131903 Date: 18-12-2014

Subject Name: Manufacturing Processes - I

Time: 02.30 pm - 05.00 pm Total Marks: 70 Instructions:




Q.1 (a) Give the Classification of Machining Processes and Also discuss the major

factors influence the selection of a suitable machining process.

07

(b) Explain size of Lathe. Also describe various types of Lathes along with their

applications and general specifications.

07

Q.2 (a) Describe Turning operation in Lathe Machine. Also discuss Shoulder Turning

and Eccentric Turning with neat sketch.

07

(b) What is Tool Signature and Tool Geometry ? Explain importance of tool angles

for single point cutting tool in brief.

07

OR

(b) Write a short note on “Turret Lathe”. 07

Q.3 (a) Enlist various operations carried out on drilling machine. Also explain Tapping,

Trepanning and Countersinking.

07

(b) Discuss briefly, with a neat sketch, horizontal boring machine. 07

OR

Q.3 (a) Explain Radial drilling machine with neat sketch. 07

(b) Give the comparison between boring and reaming. Also describe Precision

boring machine with neat sketch.

07

Q.4 (a) What is Indexing? Enlist and Discuss various types of Indexing. 07

(b) Explain Hydraulic shaper mechanism in details and also discuss the quick return

motion of Hydraulic shaper.

07

OR

Q.4 (a) Enlist various Milling Operations. Discuss the following operations.

1. Straddle Milling

2. Gear Milling

3. Face Milling

07

(b) Give the differences among shaper, planner and slotter. Discuss Briefly the

planner driving mechanism.

07

Q.5 (a) What are the advantages, limitations and applications of broaching ? Explain

“Pull broaching” and “Push Broaching”.

07

(b) What is an Abrasive? How are abrasive Classified? Enlist and explain various

abrasives used in grinding wheels.

07

OR

Q.5 (a) Write a short note on: “Band Sawing Machine” 07

(b) With neat sketch explain Center less Grinding Machine. 07

*************

1


GUJARAT TECHNOLOGICAL UNIVERSITY BE - SEMESTER–III (OLD) - EXAMINATION – SUMMER 2017

Subject Code: 131903 Date: 15/06/2017 Subject Name: Manufacturing Process-1 Time: 10:30 AM to 01:00 PM Total Marks: 70 Instructions:


Q.1 (a) Define the machine tools and broadly classify machine tools. 07

(b) Draw a block diagram of an Engine Lathe and label all parts of it. 07

Q.2 (a) List the work holding devices used on lathe and with neat sketch explain any

three of them.

07

(b) Sketch all the operations performed on lathe showing the directions of cutting

parameters.

07

OR

(b) Clearly differentiate the Capstan and Turret Lathe. 07

Q.3 (a) With a neat sketch explain the working of Radial drilling machine and Gang

drilling machine.

07

(b) Clearly differentiate the Shaper and the Planer machine. 07

OR

Q.3 (a) With a neat sketch explain the working of crank and slotted lever quick return

mechanism of a Shaper.

07

(b) Draw the geometry of a twist drill, label all elements of it and explain the

importance of each element.

07

Q.4 (a) Classify the milling machines and explain the working of any two type of

milling machines.

07

(b) Explain the mechanism of direct indexing and simple indexing. 07 OR

Q.4 (a) With a neat sketch explain the up-milling and down-milling process. 07

(b) With a neat sketch explain the working of horizontal boring machine stating its

advantages and limitations.

07

Q.5 (a) Define glazing, loading, dressing and truing for grinding wheel. 07

(b) Explain the different types of surface grinding machine with a neat sketch. 07

OR

Q.5 (a) Define the function of sawing and broaching machine and explain Band saw

machine.

07

(b) With a neat sketch explain the working of centerless grinding with work feeding

methods.

07

*************

1


GUJARAT TECHNOLOGICAL UNIVERSITY BE - SEMESTER–III(OLD) • EXAMINATION – WINTER 2016


Subject Name:Electrical and Electronics Measuring Instruments

Time: 10:30 AM to 01:00 PM Total Marks: 70 Instructions:




Q.1 (a) With the help of figure explain “ Taper turning by setting over compound slide

method”.

07

(b) Explain functions of basic parts of Lathe machine with neat

sketch.

07

Q.2 (a) Describe various types of chucks used on lathe machine 07

(b) By drawing neat sketches explain following operations which are performed

On drilling machine : (1) Counter boring (2) Counter sinking (3) Spot-facing

(4) Trepanning

07

OR

(b) Classify machine tools in detail. Explain types of motions in machine tools with

example.

07

Q.3 (a) Discuss and differentiate Up milling and Down milling process.

07

(b) Enlist different types of milling cutters. Explain any three with neat sketch.

07

OR

Q.3 (a) Draw a neat sketch of a Radial Drilling machine and discuss the important parts

briefly. Also describe advantages, limitations and applications of Radial Drilling

machine.

07

(b) Classify Milling machine. Explain principal parts of Column and Knee type

Horizontal Milling machine with neat sketch.

07

Q.4 (a) Explain principal parts of standard Planner with neat sketch. Also describe

various differences between Planner and Shaper.

07

(b) Explain with neat sketch quick return mechanism of a Shaper machine.

07

OR

Q.4 (a) Write advantages, limitations and applications of “Broaching-Machines “. 07

(b) Discuss Slotted disc mechanism in Slotting Machine

07

Q.5 (a) Explain following terminology of grinding wheel with suitable examples.

i. Grit material

ii. Grit Size

iii. Bond grade

iv. Structure of the wheel

v. Bond material

07

(b) Describe Centre Less Grinding process with standard work feeding methods. 07

2

OR

Q.5 (a) Explain in brief various alignment tests carried out on Lathe-Machine to

Check accuracy level specified by the supplier.

07

(b) With the help of neat sketch explain the “ Jig Boring Machine” 07

*************

1



BE - SEMESTER–III EXAMINATION – SUMMER 2016


Subject Name:Manufacturing Process-1

Time:10:30 AM to 01:00 PM Total Marks: 70

Instructions: 1. Attempt all questions.



Q.1 (a) Classify machine tools in detail. Explain types of motions in machine tools

with examples.

07

(b) Explain parts of engine lathe in brief with neat sketch. 07

Q.2 (a) Explain different taper turning methods. 07

(b) Explain different operations performed with the help of a lathe. 07

OR

(b) Explain single point cutting tool geometry. 07

Q.3 (a) Explain the turret indexing mechanism used in capstan lathe. 07

(b) With figure explain the twist drill nomenclature. 07

OR

Q.3 (a) Explain different types of reamers used in drilling. 07

(b) Classify boring machine. Explain horizontal boring machine & jig boring

machine with neat sketch.

07

Q.4 (a) Write classification of milling machine. Explain principal parts of column &

knee type horizontal milling machine with neat sketch

07

(b) Enumerate various milling operations. Explain any three of them with neat

sketch.

07

OR

Q.4 (a) Explain principal parts of standard planner with neat sketch. Also describe

various differences between shaper & planner.

07

(b) Explain crank and slotted link quick return mechanism in a shaper. 07

Q.5 (a) Classify sawing machine. Explain vertical band saw machine with neat sketch.

Describe various applications of sawing machine.

07

(b) Classify broaching machine. Describe various advantages and limitations of

broaching machine.

07

OR

Q.5 (a) Explain grinding wheel designation system. 07

(b) Differentiate between centre type and centre less grinding machines. 07

*************


GUJARAT TECHNOLOGICAL UNIVERSITY BE - SEMESTER–III EXAMINATION – WINTER 2015

Subject Code:131903 Date:29/12/2015 Subject Name: Manufacturing process -I Time: 2:30pm to 5:00pm Total Marks: 70 Instructions:


Q.1 (a) Draw simple sketch of engine lathe. List main parts of it and state functions of each part.

07

(b) Explain with neat sketch up milling and down milling process. Describe its advantages and limitations.

07

Q.2 (a) Discuss various lathe operations with neat sketch. 07 (b) Discuss various drilling operations with neat sketch. 07 OR (b) Draw neat sketch of radial drilling machine and name its parts, explain

its working. 07

Q.3 (a) How grinding wheel is specified? Explain in details. 07 (b) Classify machine tools in detail. Explain types of motions in machine tools with

examples 07

OR Q.3 (a) Explain with neat sketch working of horizontal boring machine. State its

advantages and limitations. 07

(b) State comparison of shaper and planer. What are advantages and disadvantages of shaping and planning as compared to other operations?

07

Q.4 (a) Sketch a typical broach tooth profile and name its elements. Explain working of pull type and push type broaching.

07

(b) Draw neat sketch of column & knee type milling machine. Label the main parts of it. State functions of each part.

07

OR Q.4 (a) List milling operations and explain following milling operations.

i. Plain milling operation. ii. Straddle milling operation. iii. Angular milling operation. iv. Face milling operation. v. Helical milling operation.

07

(b) List the principal types of metal cutting saws. Describe working of reciprocating and circular sawing machine.

07

Q.5 (a) Differentiate between Capstan and Turret lathe. 07 (b) A mild steel rod having 50 mm diameter and 500 mm length is to be turned on

a lathe. Determine the machining time to reduce the rod to 45 mm in one pass when cutting speed is 30 m/min and a feed of 0.7 mm/rev.

07

OR Q.5 (a) With the help of neat sketch explain the “ Jig Boring Machine” 07

1

(b Explain grinding process with neat sketch. What are the special features & issues to be addressed by manufacturing engineer?

07

*************

2

1


GUJARAT TECHNOLOGICAL UNIVERSITY BE - SEMESTER– III EXAMINATION – SUMMER 2015

Subject Code: 131903 Date:27/05/2015

Subject Name: Manufacturing Process-I

Time: 02.30pm-05.00pm Total Marks: 70 Instructions:




Q.1 (a) Explain hydraulic quick return mechanism in a shaper with a neat sketch. 07

(b) Explain various work holding devices of lathe machine. 07

Q.2 (a) What are the main difference between a turret lathe and a capstan lathe? 07


examples.

07

OR

(b) Enumerate operations carried out on lathe. Explain ‘setting of tailstock centre

for taper turning’ operation and ‘thread cutting’ operation both with neat sketch.

07

Q.3 (a) Write classification of milling machine. Explain principal parts of column & knee

type horizontal milling machine with neat sketch

07

(b) Enumerate various operations carried out on drilling machine. Explain any four

with neat sketch.

07

OR

Q.3 (a) List various types of drilling machine and explain with a neat sketch gang drilling

machine.

07

(b) Draw a neat sketch with label of following operation and indicate direction of

cutting parameters on it. i) Plain or slab milling ii) Face milling iii) Angular

milling iv) Form milling v)Straddle milling vi) Gang milling vii) End milling .

07

Q.4 (a) Can slotter be called as vertical shaper? Justify your answer. With neat sketch

explain operations performed on slotter.

07

(b) Classify boring machine. Explain horizontal boring machine & jig boring

machine with neat sketch.

07

OR

Q.4 (a) List various types of planers. Compare in detail Shaper and planer. 07

(b) Define Sawing. Write advantages, limitation & applications. 07

Q.5 (a) Describe the coding of grinding wheel as per IS. Explain briefly. 07

(b) Define broaching. Write advantages, limitation & applications. 07

OR

Q.5 (a) (i)Name & draw neat sketch of various grinding wheel, with its application. 03

(ii) Explain the terms a) Glazing b) Loading c) Dressing d) Truing. 04

(b) Name the various alignment tests which are conducted on lathe. Explain with the

help of neat sketch following alignment test on lathe i) levelling of the machine

ii) parallelism of spindle axis and bed.

07

*************

1


GUJARAT TECHNOLOGICAL UNIVERSITY BE - SEMESTER–III • EXAMINATION – WINTER • 2014

Subject Code: 131903 Date: 18-12-2014

Subject Name: Manufacturing Process - I

Time: 02.30 pm - 05.00 pm Total Marks: 70 Instructions:




Q.1 (a) Explain functions of basic parts of Lathe machine with neat sketch. 07

(b) Classify Milling machine. Explain principal parts of Column and Knee type

Horizontal Milling machine with neat sketch. 07

Q.2 (a) Draw a neat sketch of a Radial Drilling machine and discuss the important parts

briefly. Also describe advantages, limitations and applications of Radial

Drilling machine.

07

(b) Explain various operations carried out on Boring machine with neat sketch. 07

OR


example.

07

Q.3 (a) Enlist different types of milling cutters. Explain any three with neat sketch. 07

(b) Discuss various lathe operations with neat sketch. 07

OR

Q.3 (a) Discuss and differentiate Up milling and Down milling process. 07

(b) Enlist various alignment tests carried out on Lathe machine to check accuracy

level. Describe any two with neat sketch.

07

Q.4 (a) Explain principal parts of standard Planner with neat sketch. Also describe

various differences between Planner and Shaper.

07

(b) Explain with neat sketch quick return mechanism of a Shaper machine. 07 OR

Q.4 (a) Discuss Slotted disc mechanism in Slotting Machine 07

(b) Derive equation for calculating the taper angle by compound slide method on

Lathe operation. 07

Q.5 (a) Explain following terminology of grinding wheel with suitable examples.

i. Grit material

ii. Grit Size

iii. Bond grade

iv. Structure of the wheel

v. Bond material

07

(b) Classify Sawing machine. Explain Vertical Band Saw machine. Also discuss

various application of Sawing machine. 07

OR

Q.5 (a) Describe Centre Less Grinding process with standard work feeding methods. 07

(b) Classify Broaching machine. Explain Horizontal Pull Type Broaching machine. 07

*************

1


GUJARAT TECHNOLOGICAL UNIVERSITY BE – SEMESTER III– • EXAMINATION – SUMMER • 2014

Subject Code:131903 Date: 23-05-2014

Subject Name: Manufacturing Process - I

Time: 02:30 to 05:00 Total Marks: 70 Instructions:




Q.1 (a) Explain the construction and operation of Upright drilling machine. 07

(b) Explain the differences between the following :

(i) Up milling and Down milling (ii) Steady rest and follower rest.

07

Q.2 (a) Explain tumbler gear mechanism used in a lathe with neat sketch. 07

(b) Explain with neat sketch the quick return mechanism of a shaper. 07

OR

(b) Explain the different milling operations. 07

Q.3 (a) List the various lathe operations and explain any four lathe operations. 07

(b) What are the lathe accessories and attachments ? List the various lathe

accessories and attachments and explain the use of Mandrels on lathe.

07

OR

Q.3 (a) Distinguish simple indexing and compound indexing of a milling machine. 07

(b) Explain various drilling operations with neat sketch. 07

Q.4 (a) Describe the coding of grinding wheel as per ISI. 07

(b) List the various types of grinding machines and explain any one grinding

machine.

07

OR

Q.4 (a) Differentiate between Capstan and Turret lathe. 07

(b) Explain Broaching. Write advantages, limitations and applications of broaching. 07

Q.5 (a) Explain Jig-Boring machine. 07

(b) List the types of metal cutting saws. Describe the working of reciprocating and

circular sawing machines.

07

OR

Q.5 (a) Describe the alignment tests to check geometric accuracy of a lathe. Name

instruments and equipments needed for these tests.

07

(b) With the help of neat sketch explain Column & Knee type milling machine. 07

*************

1


GUJARAT TECHNOLOGICAL UNIVERSITY BE – SEMESTER III– • EXAMINATION – Winter 2013

Subject Code:131903 Date: 26/11/2013 Subject Name: Manufacturing Process - I Time: 02:30 to 05:00 Total Marks: 70 Instructions:


Q.1 (a) Explain with neat sketches the Primary cutting motions for lathe, drilling

machine, planning machine, shaper, grinder, milling and broaching machine. 07

(b) With a neat sketch explain horizontal boring machine and give function of its various parts.

07

Q.2 (a) List various taper turning methods and explain in detail with a neat sketch the taper turning method using the attachment.

07

(b) List various types of work holding devices used in a lathe and discuss in details with neat sketches various types of dead centres.

07

OR (b) Explain hydraulic quick return mechanism in a shaper with a neat sketch. 07

Q.3 (a) With neat sketches explain the various operations performed on lathe. 07 (b) List different indexing methods used in milling machine and explain in detail

plain indexing with a neat sketch the layout of the drive from the universal dividing head to the work piece.

07

ORQ.3 (a) List various types of grinding machines and with a neat sketch explain centre

less grinding machine. 07

(b) List various types of drilling machine and explain with a neat sketch gang drilling machine.

07

Q.4 (a) List various types of planers. Compare in detail Shaper and planer. 07 (b) Can slotter be called as vertical shaper? Justify your answer. With neat sketch

explain operations performed on slotter. 07

OR Q.4 (a) List various types of sawing machines and explain with neat sketch Band

sawing machine. 07

(b) What is broaching? Give detailed classification of the broaches. 07

Q.5 (a) With neat sketches discuss the operations that can be performed on drilling machine.

07

(b) With a neat sketch explain working of back gear arrangement on the lathe machine.

07

OR Q.5 (a) Discuss in detail the factors to be considered for selection of the grinding

wheels. 07

(b) What is the need of alignment test for a machine tool? What tools are used in these tests? List the alignment tests to be carried out on the Milling machine.

07

*************


GUJARAT TECHNOLOGICAL UNIVERSITY BE - SEMESTER–III • EXAMINATION – SUMMER 2013

Subject Code: 131903 Date: 23-05-2013 Subject Name: Manufacturing Processes - I Time: 02.30 pm - 05.00 pm Total Marks: 70 Instructions:


Q.1 (a) Draw neat sketch of hydraulic shaper mechanism and explain its working. 07

(b) Why different spindle speeds are provided on an engine Lathe? Explain. 07

Q.2 (a) Enlist types of taper turning methods used on a lathe machine. Explain with neat sketch tailstock set over method for taper turning.

07

(b) Define a Basic Machine Tool. Classify them What are the general requirements of machine tools?

07

OR (b) Explain with neat sketches different kind of (i) Slides and slide ways (ii)

general bed Structure of Base Machine Tools. 07

Q.3 (a) How stroke length and stroke position can be set on a shaper having crank and

slotted link mechanism? 07

(b) Enlist different types of milling cutters. Explain T- Slot milling with neat sketch.

07

OR Q.3 (a) Differentiate between Capstan and Turret lathe. 07

(b) Classify surface grinders. Explain with neat sketch the relative work, grinding wheel and table movements on reciprocating table type surface grinder.

07

Q.4 (a) (i) What are the essential differences between steady rest and follow rest?

(ii) Write a short note on Rotating Dead Centre. 04 03

(b) Draw a neat sketch of a radial drilling machine and name the important parts. What are advantages of radial drilling machine.

07

OR Q.4 (a) Discuss with sketch characteristics of conventional Up and Climb milling. 07

(b) Enlist common methods of indexing using dividing head. Explain any two with suitable examples.

07

Q.5 (a) What could be the possible causes for the following drilling problems?

(i) Breaking of drill (ii) Hole too large (iii) production of rough hole and (iv) Breaking down of outer corner of cutting edges.

07

(b) Grinding wheel characteristics or performance of a grinding wheel depends on types of abrasive, grain size, structure and bonding material. Discuss the effect of each.

07

OR Q.5 (a) Explain with neat sketch Horizontal pull type broaching machine 07

(b) What are the common geometrical tests are performed on an engine lathe? For what purpose they are performed? Explain any three alignment test with neat sketch.

07

*********

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