Roll Number:
Thapar Institute of Engineering & Technology
Department of Mechanical Engineering
Mid Semester Examination October,
2023
BE- 1ST Semester UES102: Manufacturing Processes
Time: 02 Hours; MM: 100 Name of Faculty: RSJ, RTK, DM, SCS, APS, KPC, HTK,
PCY
NOTE: Do all questions in sequence; assume suitable missing data, if any.
Mention your group number on the top of answer sheet.
Support your answers with neat sketches wherever required.
All questions are compulsory and carry equal marks.
Use handout for Que 1.
Q1. (a) An aluminum component required to be manufactured on CNC Lathe machine as shown in Figure 1. The 24 L3
operations required on the component are multiple turning, facing and threading. Write a manual part program [CO1]
using cycles. Consider following information while writing the part program.
a. Spindle speed in turning and facing is 2300 rpm. For drilling and threading, speeds are 1500 and 700 rpm
respectively.
b. Feed rate for rough and finish turning are 95 and 45 mm/min respectively.
c. Depth of cut for rough cut turning is 0.5 mm and finishing allowance is 0.3 mm with tool retracts of 0.5 mm.
d. Facing (using facing cycle) required to be done for 5 mm using maximum depth of cut of 1 mm with feed rate
of 90 mm/min.
e. Consider the thread angle of thread (Metric) as 60o with 10o relief angle. The number of finishing passes
required are five. Finishing allowance is 0.05 mm. Take minimum depth of cut and depth of cut for first pass as
0.02 mm and 0.2 mm respectively.
f. All dimensions given in Figure 1 are in mm.
Figure 1
(b) Why was the negative rake angle preferred while turning brittle material? Draw top view, bottom view and 1+3+2 L2
side view for the negative rake (both) angles tool. Also specify the order of all angles/radius in tool signature. [CO1]
(c) With the help of graph, show the variation in hardness of different tool materials (HSS, Ceramics, Cast alloy 4 L1
and Carbides) with respect to temperature. [CO1]
Q2 (a) In the automotive industry, a shaft is produced from a 600 mm long and 32 mm diameter stainless steel rod
by turning on a lathe machine in two rough cut (with same depth of cut in each pass) and one finish cut. The 12 L3
machining conditions for turning this rod are set to be different for rough and finish cut as given in the table [CO1]
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below. This shaft is required to be fit in a bearing with 28 mm internal diameter. The reduction in diameter in
the finish cut should be 1 mm only. Calculate the material removal rate (in mm 3/min) in both rough and finish
cut, and total time required for machining of steel rod (in min).
Machining parameters Rough Cut Finish Cut
Spindle rotation (rpm) 300 400
Axial feed (mm/min) 150 100
10
(b) Define chip welding and its disadvantages. Briefly explain the conditions that promote chip welding and [CO1] L1
how it can be avoided.
(c)A rail of high carbon steel is to be rolled at 800°C from a bloom. Identify the type of rolling process in terms 10 L4
of temperature and configuration. State advantages and disadvantages of working at this temperature if the [CO2]
melting temperature of low carbon steel is 1540°C.
Q3 (a) A series of hot rolling operations are to be used to reduce the thickness of a plate from 100 mm down to 85 12 L3
mm. Roll diameter is 400 mm, coefficient of friction between rolls and work is 0.15 and initial work velocity is [CO2]
10m/min. Assuming the draft to be equal on each pass, determine: (a) minimum number of passes; (b) draft for
each pass; (c) final exit velocity of sheet, if width of the sheet is increased by 1.5% in each pass.
(b) Explain barreling effect. In which type of forging process, it can occur explain with schematics? 10 L1
[CO2]
(c) A rectangular shape of blank 40 mm x 30 mm is to be cut from a half hard cold rolled steel strip of 3 mm
thickness with allowance for the material is 0.075. Determine (i) the dimensions of the punch and dies, and (ii) 12 L3
the blank force if tensile and shear strength of strip material is 450 MPa and 300 MPa respectively. [CO2]
Hand Out (Lathe) Multiple turning cycle: G71 U_ R_
G00 X_ Z_ – Rapid transverse G71 P_ Q_ U_ W_ F_
G01 X_ Z_ F_– Linear motion with feed G70 P_ Q_ F_ – Finishing cycle
G02 X_ Z_ R_F_– Tool movement in clockwise direction Facing Cycle: G94 X_ Z_ F_
G03 X_ Z_ R_F_– Tool movement in anti-clockwise direction Drilling cycle: G74 R_
G20 – Inches mode G74 X_ Z_ Q_ F_
G21 – Metric mode (in mm) Threading Cycle: G76 P(m) (r) (a) Q_R_
G28 U_ W_ – Go to machine home position in incremental G76 X_ Z_ P_ Q_ F_
mode Miscellaneous code (common)
G98 – Feed in mm/min M03 – Spindle rotation in clockwise direction
U – Incremental mode in X- axis M05 – Spindle stop
W – Incremental mode in Z- axis M06 – Tool change
X – Absolute mode in X- axis M30 – Program Stop and Rewind
Z – Absolute mode in Z- axis
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