Subject Code: BME051
Subject Name: Advanced Manufacturing Processes
Course: B.Tech (Semester V)
Maximum Marks: 70
Duration: 3 Hours
Exam Year: 2024–25
Sections: A, B, and C
SECTION A – Short Answer Questions (2 × 7 = 14 Marks)
Attempt all questions briefly.
Define Machining and Machinability.
What is a Pattern? Give any two types of patterns.
Define Allowance. Give any two types of allowances used in casting.
What is Casting? Give any two disadvantages of this process.
What is Welding? List the types of welding used in manufacturing.
What is High Energy Rate Forming (HERF) process?
What is the main difference between Additive Manufacturing and Traditional Manufacturing?
SECTION B – Medium-Length Questions (7 × 3 = 21 Marks)
Attempt any three of the following.
Explain how Water Jet Machining (WJM) achieves precise cuts without thermal damage.
Explain Evaporative Casting with a neat diagram.
Describe Ultrasonic Welding (USW) — explain how high-frequency vibration and pressure create joints.
Explain the Electromagnetic Forming (EMF) process and list its advantages.
What is Time Compression in product development, and why is it important?
SECTION C – Long/Analytical Questions (7 × 5 = 35 Marks)
Q3. Machining
a. What is Abrasive Jet Machining (AJM)? Explain its working with a neat diagram and discuss effects of standoff distance and abrasive grit size on material removal rate.
OR
b. What is Water Jet Machining (WJM)? Explain its working and discuss how varying parameters affect cutting efficiency.
Q4. Casting
a. Explain the Continuous Casting process — include steps and advantages.
OR
b. Discuss Ceramic Shell Casting — highlight its benefits for high-temperature alloys, including surface finish and dimensional accuracy.
Q5. Welding
a. Explain Electron Beam Welding (EBW) with a neat sketch, limitations, and applications.
OR
b. Explain Laser Beam Welding (LBW) with a neat sketch, limitations, and applications.
Q6. Forming
a. Describe the Contour Roll Forming process and how it continuously shapes metals.
OR
b. Explain Explosive Forming, describing how shockwaves deform metal effectively.
Q7. Additive Manufacturing
a. Why is Additive Manufacturing (AM) important? Classify different AM systems.
OR
b. What are the key process parameters that influence the quality of parts produced by Powder Bed Fusion?
Key Topics for Preparation
Non-traditional machining: AJM, WJM, EDM, ECM
Casting methods: Continuous, Evaporative, Ceramic shell
Advanced welding: EBW, LBW, Ultrasonic welding
High-energy forming: Electromagnetic and Explosive forming
Additive manufacturing: Classification, Powder bed fusion parameters
Product development: Time compression and modern production speed
Study Tips
Draw clear, labeled diagrams for every process (AJM, EBW, LBW, EMF).
Revise working principles, advantages, limitations, and applications for each process.
Remember comparisons — Additive vs Traditional manufacturing, AJM vs WJM.
Understand process parameters — pressure, grit size, feed rate, energy input, etc.
Practice numerical or theoretical derivations wherever applicable (like material removal rate).
