(SEM IV) THEORY EXAMINATION 2023-24 MANUFACTURING PROCESSES

This document is a B.Tech (Semester IV) Theory Examination Question Paper for the subject BME403 – Manufacturing Processes, conducted in the academic session 2023–2024.
It is a 3-hour, 70-mark examination designed to evaluate a student’s understanding of traditional and non-traditional manufacturing, machining, forming processes, grinding, welding, tool geometry, EDM, and modern machining methods.
 

The paper is structured into three main sections—A, B, and C—progressing from short theory questions to detailed explanations and numerical/analytical problems.

SECTION A – Short Answer Questions (14 Marks)

Seven short 2-mark questions covering the fundamentals of manufacturing:

Meaning of Manufacturing                             Definition of Allowance in casting

Meaning of Rake Angle in machining              Definition of Tool Life

Meaning of Glazing in grinding                        Definition of HAZ (Heat Affected Zone) in welding

Concept of Non-Traditional Manufacturing Processes

This section evaluates basic terminology and conceptual clarity.

SECTION B – Descriptive & Conceptual Questions (21 Marks)

Students must attempt any three of the following:

a. Drawing vs Deep Drawing

Difference, defects, and causes during sheet metal drawing.

b. Tool Geometry (ASA System)

Explanation of tool angles and designation of a cutting tool under the ASA reference system.

c. Cylindrical vs Centerless Grinding

Key differences in:

Workholding                         Process accuracy

Productivity                          Applications

d. Resistance Welding

Advantages and disadvantages of resistance welding processes.

e. EDM (Electrical Discharge Machining)

Working principle with neat diagram + advantages & disadvantages.

SECTION C – Analytical, Numerical & Process-Based Questions (35 Marks Total)

Each question contains two parts; one must be attempted from each.

3. Powder Metallurgy / Rolling Analysis (7 Marks)

Option 3(a)
Define Powder Metallurgy (PM), its advantages, disadvantages, and applications.

Option 3(b)
Define Rolling process and derive expressions for:

Rolling Force                      Work

Power consumption

4. Machining / Shear Angle Numerical (7 Marks)

Option 4(a)
Define Machining and explain different chip formations (continuous, discontinuous, built-up-edge).

Option 4(b)
Given:

Rake angle = 12°                         Uncut thickness = 0.81 mm

Chip thickness = 1.8 mm
Find shear angle using orthogonal machining theory.

5. Lapping & Honing / Grinding Wheel Wear (7 Marks)

Option 5(a)
Short notes on:

Lapping                                       Honing

Option 5(b)
Wear mechanisms of grinding wheel:

Attritious wear                             Fracture

Bond fracture

6. Welding Failures & Precautions / TIG & MIG Welding (7 Marks)

Option 6(a)
Why welding joints fail + precautions to increase weld life.

Option 6(b)
Explain TIG and MIG welding with neat diagrams.

7. Laser Beam Machining / Abrasive Jet Machining (7 Marks)

Option 7(a)
What is a Laser? Explain LBM (Laser Beam Machining) with diagram.

Option 7(b)
Explain Abrasive Jet Machining (AJM) with diagram and why abrasive particles are not recycled.

Overall Purpose of the Document

This exam paper evaluates a student's proficiency in:

Machining fundamentals and tool geometry

Sheet metal operations (drawing, deep drawing)

Grinding methods and tool wear

Welding processes (TIG, MIG, resistance welding, HAZ)

EDM and Non-Traditional machining processes

Powder metallurgy and rolling operations

Lapping, honing, and finishing processes

Modern machining processes (LBM, AJM)

Analytical ability through numerical questions (chip thickness, shear angle)

It includes conceptual definitions, derivations, explanations, diagrams, and numerical calculations—ensuring strong assessment of manufacturing engineering concepts.