(SEM IV) THEORY EXAMINATION 2022-23 MANUFACTURING PROCESSES

SECTION A – What These Questions Cover

Section A contains 10 short, concept-based questions on fundamental topics of manufacturing processes.
These questions test a student's basic understanding of casting, metal forming, machining, grinding, welding, and non-conventional machining.

This section includes topics such as machining allowance, differences in forming processes (wire drawing vs. extrusion), the distinction between cutting tools and machine tools, Taylor’s tool life relation, grinding defects (glazing vs. loading), friability of abrasives, purpose of flux in welding, consumables in arc welding, comparison between conventional and non-conventional machining, and reasons abrasives are not reused in AJM.
The purpose of this section is to check if the student is familiar with basic definitions, reasons, differences, and concepts in manufacturing engineering.

SECTION B – What These Questions Cover

Section B requires answering any three descriptive or numerical-based questions.
These questions include casting design (riser and Caine’s method), Merchant force circle and shear angle relation, grinding wheel grade and specification, TIG & MIG welding process, and water jet machining.

The focus here is on the student’s ability to explain processes in detail, understand tool geometry and cutting mechanics, interpret grinding wheel coding, understand fusion welding techniques with diagrams, and describe modern machining processes with principle and applications.
This section evaluates understanding of process design, force analysis, material removal concepts, and thermal/mechanical aspects of manufacturing processes.

SECTION C – What These Questions Cover

Section C contains long, explanatory questions, where one part must be attempted from each pair.

It covers heat transfer during solidification of metals in casting, which includes temperature distribution diagrams, or comparison of hot working vs. cold working along with benefits of metal forming.
Another part asks about tool wear (crater and flank wear) with diagrams, or tool life calculation using Taylor’s formula.
There are also questions on abrasives in grinding, dressing vs. truing, super-finishing processes (honing, lapping, polishing).
Next parts include friction welding, HAZ and weld decay, LASER machining, and electro-chemical machining (ECM) with metal removal rate calculation.

This section tests the ability to describe, compare, derive, illustrate with diagrams, and solve advanced process-related numerical problems.
It aims to measure deeper understanding of material behavior, heat effects, tool wear, advanced machining, and finishing processes.