(SEM IV) THEORY EXAMINATION 2024-25 MANUFACTURING PROCESSES

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.