Btech Degree VIII Semester (Supplementary) Examination

Sub: ME 803 Production Technology

Time : 3 Hours Max. Marks : 100
Part A
I(a). Mention the various limitations of Electro Discharge Machining
process in metal cutting.
(b). What are the advantages of Chemical Milling process ? Mention few
areas where Chemical Milling is used.
(c). What is meant by speed diagram ? Draw all possible distributions of
speeds for a 2 x 3 system.
(d). Explain 'stepped' and 'stepless' regulation of speeds.
(e). Mention the advantages and limitations of powdered metals.
(f). Explain the process of 'Atomization' in the preparation of metal
powders.
(g). Give a brief description on the various types of fluid logic elements.
(h). Explain the hydraulic circuit of shaper machine with suitable sketch.
(8 x 5 = 40)

Part B
II. Explain the procedure followed in the design of a speed box. (15)
OR
III. With the help of a neat sketch explain the working of a Positive
Infinitely Variable drive (15)
IV. A hole of 1.83 mm diameter is to be drilled to a depth of 7.48mm in
steel sheet by EDM method using brass electrode.The surface finish
required is to be 20 micron. Determine the source voltage to be set up
for an R-C circuit setting of 100 ohms and120 micro-farads
respectively. Also find out the time required for drilling. Assume
sparking period as 100 -sec.
Take discharging power = 0.8 times power delivered. Given surface
roughness = K1(CU2)K2tpK3 microns,where K1,K2,K3 are constants,
values depending on electrode and workpiece are respectively 13,0.45
and 0.22. C Capacitance of condenser in farads,U Voltage across
capacitor, tp pulse duration in -sec.
Metal removal rate(MRR) =1.42 tcU2 mm2/sec (tc charging time).(15)
OR
V. A hole hole is to be drilled in a 20mm thick tungsten carbide sheet by
ultrasonic method. The slurry is made of boron carbide(15 micron
radius) mixed with water. The static stress is 1.4 kg/cm2 and the
amplitude of tool oscillation is 0.025mm. The machine operates at
25,000 cycles/sec. The compression fracture strength of WC is 225
` kg/mm2. Calculate the time required to perform drilling. Assume that
one out of ten pulses are effective. Consider MRR = 5.9f (Ry0) (/H)
where f = frequency in c.p.s.,R = Radius of grit in mm, y0= amplitude
of oscillation, = Stress developed in tool in kg/mm2, H= x Fracture
strength. (15)
VI. Explain method by which Tungsten carbide tools are manufatured.
(15)
OR
VII. Discuss the various advantages and disadvantages of Powder
Metallurgy. (15)
VIII. Estimate the total time required for machining a mild steel rod of
diameter 40mm and length 150mm as per requirements given.
80 mm length to be turned to 35mm and 30 mm length of 35mm
diameter to be turned to 30mm diameter. Depth for rough cut to be
not more than 1mm. A finishing cut of depth 0.5mm to be given.
Cutting speed = 60m/min. Feed = 0.8mm/min (15)
OR
IX. Discuss the procedure for estimating the cost of a product produced
in a foundry shop. (15)