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2003 Course Process Planning & Tool Selection

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Total No. of Questions : 12] P980 [Total No. of Pages : 4 [3664]-162 B.E. (Production Engg.) PROCESS PLANNING AND TOOL SELECTION (2003 Course) (411089) Time : 3 Hours] [Max. Marks : 100 Instructions to the candidates: 1) Answer 3 questions from Section-I and 3 questions from Section-II. 2) Answers to the two sections should be written in separate books. 3) Neat diagrams must be drawn wherever necessary. 4) Figures to the right indicate full marks. 5) Use of electronic pocket calculator is allowed. 6) Assume suitable data, if necessary. SECTION - I Q1) a) Define the following terms: i) Part print ii) Specifications iv) Process picture v) Equipment [6] iii) Routing vi) Assembly chart b) Explain in detail with a neat line diagram how the manufacturing processes are classified. [10] OR Q2) a) Explain the functions of process engineering department. [8] b) What is an organization chart? Explain the significance of process engineer and product engineer location in the organization. [8] Q3) a) Explain the following with symbols used on part print: i) Flatness ii) Concentricity iii) Angularity iv) Squareness [8] b) What key points are to be considered in determining the nature of the work to be performed and functional surfaces on the workpiece? [8] OR [4] Q4) a) Distinguish between the angular and rectangular dimensions. b) What is the purpose of grouping related surfaces or areas? Explain. [8] c) Define the following: [4] i) Superfluous dimensions ii) Functional dimensions P.T.O. Q5) a) What causes workpiece variations? What are the variables which interface with workpiece control? [8] b) What is a tolerance chart? What are the symbols used in tolerance chart? Why is it necessary to balance a tolerance chart? [10] OR Q6) a) What are the rules for locating long cylindrical and short cylindrical work pieces? Explain with a neat line diagram. [8] b) Explain the following w.r.t work piece control. i) Dimensional control ii) Mechanical control [10] SECTION - II Q7) a) Explain the steps involved in machine selection method with a neat flowchart. [8] b) What are the factors affecting machine selection? Explain. [4] c) Distinguish between general purpose machines and special purpose machines? [4] OR Q8) a) What are the factors affecting tool selection? Explain in brief. [8] b) What are the rules to be followed while assigning operation numbers in process sheet design? [4] c) Explain the difference between commercial tooling and regular tooling. [4] Q9) a) What are the advantages and limitations of computer aided process planning? [6] b) Explain in detail the steps involved in variant process planning. List any four CAPP software packages used in manufacturing industry. [10] OR Q10) a) Explain the following with examples: i) Basic processes ii) iii) Qualifying operations [12] Principal processes iv) Secondary operations b) Explain the differences between product critical areas with process [4] critical areas with a sketch. [3664]-162 -2- Q11) Prepare the process sheet for the welded shaft support shown in Fig.l. which is to be manufactured on batch production basis. The process sheet must contain manufacturing plan with operation sequence, equipment, tooling, process parameters and sample calculation of operation time. Design a proper work holding device to drill and bore 28 mm dimension. Study the welding symbols carefully before planning. [18] Material - Mild Steel [3664]-162 -3- OR Q12) Prepare the process sheet for a special bolt shown in Fig.2. which is to be manufactured on batch production basis with 1200 Nos/Week. The process sheet must contain detailed manufacturing plan with operation sequence, equipment, tooling, process parameters and sample calculations of operation time. Design a milling fixture to machine the flats and slot in the head of a special bolt. [18] Material - C - 40 steel rrr [3664]-162 -4-

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