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MU Mechanical Engineering (Semester 4)
Production Process 2
December 2011
Total marks: --
Total time: --
INSTRUCTIONS
(1) Assume appropriate data and state your reasons
(2) Marks are given to the right of every question
(3) Draw neat diagrams wherever necessary

Write short note on following:-
1 (a) Lathe tool dynamometer.
5 M
1 (b) Types of bushes.
5 M
1 (c) Force analysis & power calculation in drilling.
5 M
1 (d) Types of chips.
5 M

2 (a) Design and sketch a suitable die to produce 10,000 pieces of M.S. work piece of diameter 35mm and 2mm thick. The material is having shear strength of 400N/mm2. Assume suitable data if necessary. Write the necessary design steps.
10 M
2 (b) What factors should be considered for selecting appropriate press for a given job? Discuss the method of reducing cutting forces in press tool with neat steps.
10 M

3 (a) Prove that the relationship
2θ + β + γ = π/2
holds good in orthogonal cutting, where θ= shear angle, β= friction angle, γ= rake angle. Also state your assumptions.
10 M
3 (b) During orthogonal machining with rake angle 100 and uncut thickness 0.125mm, the values of Ft and Fc are found to be 217N and 517N respectively. Average chip thickness=0.43mm, width of chip=2mm, cutting speed=120m/min. Compute: chip thickness ratio, shear angle, resultant force, shear force, normal compressive force, frictional force, merchant?s constant, cutting power consumption, shearing power consumption and frictional power consumption
10 M

4 (a) Discuss the different cutting tool material with their advantages and limitations.
10 M
4 (b) Explain planetary and cluster rolling mills with neat sketches.
5 M
4 (c) Write short note on "Mechanism of Rolling Process"
5 M

5 (a) Explain the various steps involved in design of circular pull type broach. Draw the neat sketches.
10 M
5 (b) Compare jigs and fixture and explain locating and clamping elements used in jigs and fixtures.
10 M

6 (a) Explain thread rolling and rolling defects.
7 M
6 (b) Explain the design principles for turning fixtures.
5 M
6 (c) Compare compound and progressive die with neat sketches.
8 M

7 (a) A 200 mm long and 30 Mm bar is being turned on lathe with a feed of 0.25 mm/rev. The operating cost is 5 paise/min while tool cost is Rs.1 per cutting edge. Tool changing time is 1 min. for each cutting edge. Compare the machining cost per component while operating under most economical condition for following materials:-
 Materials Tool Life Equation X VT0.1 = 67 Y VT0.1 = 90
10 M
7 (b) Design and draw circular form tool for forming the work piece for shape given in the figure. The bar is 60mm diameter steel bar. Assume rake & clearance angle 12° and 10° respectively. The form tool is HSS.
10 M

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