This document contains the complete B.Tech (Semester IV) Theory Examination 2024–25 question paper for Manufacturing Processes (BME403). The paper spans two printed pages, carries 70 marks, and assesses a student’s understanding of casting, welding, forming, machining, grinding, advanced manufacturing technologies, tool geometry, and non-conventional machining processes.
Section A – Short Conceptual Questions (14 Marks)
Section A includes seven 2-mark questions, covering the foundational concepts of manufacturing. Based on Page 1, it covers:
Purpose of machining allowance in casting
Casting defects & residual stresses
Definition of Rapid Prototyping
Single-point vs multi-point cutting tools
Meaning of friability in grinding
Difference between brazing and soldering
Difference between conventional and non-conventional machining
These questions evaluate basic knowledge of various manufacturing operations.
Section B – Medium-Length Analytical Questions (21 Marks)
Students attempt any three out of five 7-mark questions. As seen on Page 1, this section explores deeper understanding of core processes:
Hot Working vs Cold Working
Includes explanation, comparison, and suitability for wire drawing.
Tool Geometry (ASA System)
Understanding of tool angles and notation used in the ASA reference system.
Grinding Wheel Grading
Interpretation of grinding wheel specification
“51-C-30-M-5-V-17”
according to ISO standards.
TIG & MIG Welding
Working principles with neat sketches, arc characteristics, shielding gases.
Non-Conventional Machining
Short notes on:
Electron Beam Machining (EBM)
Electrochemical Machining (ECM)
This section checks understanding of both traditional and modern manufacturing methods.
Section C – Long, Higher-Order Questions (35 Marks)
Students must attempt one part from each question (Q3 to Q7). These require detailed derivations, diagrams, or numerical calculations.
Q3 – Extrusion Process / Solidification in Casting
Definition, working, advantages, limitations & shapes formed by extrusion
OR
Solidification curve of pure metal & heat transfer mechanism during casting.
Q4 – Orthogonal Cutting / Tool Wear
Given machining data (chip thickness, forces, rake angle, cutting speed), calculate:
Shear angle
Friction angle
Shear stress
Power consumption
(Data shown clearly on Page 2)
OR
Detailed explanation of flank wear and crater wear with diagrams.
Q5 – Superfinishing / Grinding Wheel Wear
Definition of superfinishing with notes on Honing, Lapping, Polishing
OR
Explanation of grinding wheel wear, dressing vs truing.
Q6 – Resistance Welding / HAZ in Arc Welding
Principle & heat balance of resistance spot welding
OR
Meaning of HAZ, and explanation of weld decay with diagrams.
Q7 – Abrasive Jet Machining / Laser Beam Machining
Working of AJM with neat diagram + effect of grit size & standoff distance
OR
Full principle and working of Laser Beam Machining (LBM) with diagram.
These questions assess advanced application, numerical problem-solving, and conceptual explanation.
