Mark Scored:

KATHMANDU UNIVERSITY
End Semester Examination
August/September, 2017
Level : B. E. Course : MEEG317
Year : III Semester : II
Exam Roll No. : Time: 30 min F. M. : 20

Registration No.: Date :

SECTION “A”
[20 Q × 1 = 20 marks]

Tick the most appropriate answer.

1. Increasing strain rate tends to have which one of the following effects on flow stress during
hot forming of metal.
(a) decreases flow stress (b) has no effect,
(c) has no relations between them (d) increases flow stress

2. A roughing operation generally involves _______________ combinations of cutting

conditions.
(a) high v, f, and d (b) high v, low f and d
(c) low v, high f and d (d) low v, f, and d
Wherev = cutting speed, f = feed, and d = depth of cut?

3. The mechanism of chip formation in machining is best described by ____________________

(a) compression (b) fracture failure (c) shear deformation (d) tensile failure

4. According to the Merchant equation, an increase in rake angle means___________________

(a) decrease in friction angle (b) decrease in power requirements
(c) decrease in shear plane angle (d) increase in cutting temperature

5. How many elements of tool geometry are required to completely specify a single-point tool?
(a) two (b) five (c) seven (d) ten

6. For a given weight of metallic powders, the total surface area of the powders is increased by
______________________
(a) larger particle size (b) higher shape factor
(c) smaller particle size (d) lowersieve number

7. Which of the following statements are correct in the context of metallic powders.
(a) porosity - packing factor = 1.0 (b) packing factor = 1/porosity
(c) packing factor = - porosity (d) packing factor = bulk density/true density

8. Which one of the following relation is commonly used in powder metallurgy?

(a) 0.5Tm
(b) 0.6Tm
(c) 0.7Tm
(d) 0.8Tm
Where, Tm = melting temperature of the metal on an absolute scale.
9. A screen with 325 mesh count has wires with a diameter of 0.035 mm. What is the maximum
particle size that will pass through the wire mesh?
(a) 0.0025mm (b) 0.034 mm (c) 0.035mm (d) 0.043mm

10. ___________________ processes would be appropriate for cutting a hole of 0.075 mm

diameter through a plate of aluminum that is 1.6 mm thick.
(a) abrasive jet machining (b) chemical milling
(c) EDM (d) laser beam machining

11. The metal removal rate in electric discharge machining depends on ____________________
(a) discharge current (b) hardness of the work metal
(c) melting temperature of the tool (d) tensile strength of the work metal?

12. In water jet cutting and abrasive water jet cutting, the separation between the nozzle opening
and the work surface is called ______________________
(a) gap size (b) orifice (c) overcut (d) standoff distance

13. The etch factor in chemical machining is equal to ____________________________

(a) CIt (b) d/u (c) u/d (d)C/d
Where C = specific removal rate, d = depth of cut, I = current, t = time, and u = undercut

14. A stepper motor is ______________________________

(a) actuator (b) sensor (c) pulse counter (d) interface device

15. The input/output relationship of a sensor is called ________________________

(a) analog (b) converter (c) sensitivity (d) transfer function

16. The APT command GORGT is __________________________________

(a) continuous path command
(b) geometry statement involving a volume of revolution about a central axis
(c) name of the humanoid in the last Star Wars movie
(d) point to point command

17. The physical layout of a flexible manufacturing system is determined principally by

________________________
(a) computer system (b) material handling system
(c) part family (d) processing equipment

18. The transfer line is closely associated with ________________________ types of production
operations.
(a) assembly (b) machining
(c) press working (d) automotive chassis fabrication

19. A route sheet is a document whose principal function is ______________________________

(a) continuous improvement
(b) design for manufacturability
(c) provides authorization for material handlers to move the part
(d) specifies the process plan

20. ________________________ RP technologies uses solid sheet stock as the starting material.
(a) droplet deposition manufacturing (b) fused-deposition modeling
(c) laminated-object manufacturing (d) selective laser sintering
 KATHMANDU UNIVERSITY
End Semester Examination
August/September, 2017
Level : B. E. Course : MEEG 317
Year : III Semester : II
Time : 2 hrs. 30 mins. F. M. : 55
SECTION “B”

Attempt ANY FIVEquestions. Assume suitable data if necessary.Neat diagram must be drawn
wherever necessary.Figure to the right indicate full mark.

Q. No. 1
a. Name and briefly describe the four types of chips that occur in metal cutting. [3]
b. In a turning operation on stainless steel, cutting speed = 150 m/min, feed = 0.25 mm/rev, and
depth of cut = 7.5 mm. How much power will the lathe draw in performing this operation if
it’s mechanical efficiency = 90% and the appropriate specific energy value is 2.8 J/mm3. [3]
c. Calculate the average tool–chip interface temperature for an orthogonal cutting of steel using
cemented carbide tool under the following conditions. [5]

Tool rake angle 100

Shear stress of the work material 200 N/mm2
Uncut chip thickness 0.1 mm
Width of cut 2 mm
Chip thickness ratio 0.25 mm
Cutting speed 1 m/s
Coefficient of friction 0.0674
Density of work piece 6000 kg/m3
Specific heat of the work material 500 J/kg K
Thermal conductivity of the work 50 W/m K
material
Tool–chip contact length 0.25 mm

Q. No. 2
a. How non-traditional machine processes are classified. [3]
b. Much of the work at the Cut-Anything Company involves cutting and forming of flat sheets
of fiber-glass for the pleasure boat industry. Manual methods based on portable saws are
currently used to perform the cutting operation, but production is slow and scrap rates are
high. The foreman says the company should invest in a plasma arc cutting machine, but the
plant manager thinks it would be too expensive. What do you think? Justify your answer by
indicating the characteristics of the process that make PAC attractive or unattractive in this
application. [4]
c. A square hole is to be cut using ECM through a plate of low alloy steel that is 12 mm thick.
The specific removal rate for this steel is 3.7 x 10-2 mm3/A-s. The hole is 35 mm on each
side, but the electrode used to cut the hole is slightly less than 35 mm on its sides to allow for
overcut, and its shape includes a hole in its center to permit the flow of electrolyte and to
reduce the area of the cut. This tool design results in a frontal area of 245 mm2. The applied
current = 1200 amps. (a) Using an efficiency of 95%, how long will it take to cut the hole?
(b) If the tool were designed with a frontal area equal to the hole size, how long will it take to
cut the hole? [4]
Q. No. 3
a. Explain the difference between infiltration and impregnation in powder metallurgyGive at
least two examples of each. [3]
b. In a certain pressing operation, the metallic powder fed into the open die has a packing factor
of 0.5. The pressing operation reduces the powders to 70% of their starting volume. In the
subsequent sintering operation, shrinkage amounts to 10% on a volume basis. Given that
these are the only factors that affect the structure of the finished part, determine its final
porosity. [3]
c. Determine the shape factor for metallic particles of the following ideal shapes: (a) sphere, (b)
cubic, (c) cylindrical with length-to-diameter ratio of 1:1, (d) cylindrical with length-to-
diameter ratio of 2:1, and (e) a disk-shaped flake whose thickness to diameter ratio is 1:10.
[5]

Q .No.4
a. Use the Euler-Poincare law to verify if the following objects are topologically valid: (a) a
rectangular block with a rectangular through hole, (b) a circular cylinder, and (c) a
rectangular block with a circular through hole. [6]

b. Find the composite transformation matrix that rotates the rectangle shown below at the point
S= [3, 2] a 300 angle. Note that the corner points of the rectangle are P1 = [1,1], P2= [2,1],
P3= [2,3] and P4 = [1,3]. [5]

Q. No.5
a. A lead-screw with an 8mm pitch drives a worktable in an NC positioning system. The lead-
screw is powered by a stepping motor with 180 step angles. The worktable is programmed to
move a distance of 150 mm from its present position at a travel speed of 400 mm/min.
Determine (a) the number of pulses to move the table the specified distance, and (b) the
motor speed. [2]
 b. Write a CNC Milling manual part program manuscript for the following Figure. [4]
Note: Program should follow the serial order provided in the question.

c. Write the complete APT part program to profile mill the outside edges of the part shown in
the Figure. The part is 15 mm thick. Tooling = 30 mm diameter end mill with four teeth,
cutting speed = 150 mm/min, and feed = 0.085 mm/tooth. Use the lower left corner of the
part as the origin in the x-y axis system. Two of the holes in the part have already been
drilled and will be used for clamping the part during profile milling. Postprocessor call
statement is MACHIN/MILL, 06. [5]

Q. No. 6
a. What are the three methods for solving the problem of grouping parts into part families? [3]
b. What are the typical objectives when implementing cellular manufacturing? [4]
c. A tube with a rectangular cross section is to be fabricated by stereolithography. Outside
dimensions of the rectangle are 40 mm by 70 mm, and the corresponding inside dimensions
are 32 mm by 62 mm (wall thickness = 4 mm except at corners). The height of the tube (z-
direction) = 50 mm. Layer thickness = 0.10 mm, and laser spot diameter = 0.25 mm. The
beam velocity across the surface of the photopolymer = 750 mm/s. Compute an estimate for
the cycle time to build the part, if 20 s are lost each layer for repositioning and recoating.
Ignore setup time. [4]