ME6005-PROCESS PLANNING AND COST ESTIMATION

2MARK QUESTIONS
PART - A
UNIT -1
1)What is meant by process planning?
2) What are the information that a root sheet can provide?
3) What are the material selection parameters?
4) What are the stages of machine selection process?
5) Differentiate between variant and generative CAPP systems.
UNIT -2
1) List the major factors that are to be considered during the selection of feed rate.
2) What is the generally recommended value of depth of cut for turning and boring operations?
3) Compare and contrast between jigs and fixtures.
4) List the seven statistical tools of quality that are use in quality control.
5) What is meant by break-even point?
UNIT -3
1)What are the objectives of cost estimation?
2) What are different types of estimate?
3) Define costing or cost accounting.
4) Name the various elements of cost.
5) What is meant by total cost?
UNIT 4
1) 1) What are the various losses considered while calculating the material cost for a forged
component?
2) How can you determine the size of the stock in forging?
3) What are the various elements considered while calculating the cost of a welded joint?
4) A butt joint between two square metal plates of 250cm x 250cm is made using electric arc
welding. If the rate of welding is 5 meter/hour. Calculate the time required to complete ten
such welding operations.
5) What are the various losses considered while calculating direct material cost for a casting?
UNIT-5
1) What do you mean by tool approach and tool overtravel? Show diagrammatically how
these terms are related to the length of cut for a cutting operation.
2) Distinguish between feed and depth of cut.
3) Write the formula to calculate the machining time for a shaping/planning/slotting
operation.
4) Write the formula for calculating the grinding time for a cylindrical grinding operation.
5) Give the formula for calculating over-travel, when cutter diameter is bigger than width of
work piece during face milling.
 PART-B
16 MARKS QUESTIONS
1) What are the methods(or)approaches of process planning? Explain briefly.(16)
2) List and explain the various factors considered for the production equipment and tooling
selection.(16)
3) (i)Explain briefly about selection of quality assurance methods.(10)
(ii) List out the set of documents that are required for process planning.(6)
4)(i) Explain in detail the process planning activities.(10)
(ii) What are the factors to be considered during designing and selection of jigs and
fixtures?(6)
5) Calculate prime cost ,factory cost, production cost , total cost and selling price per item from
the data given below in table for the year 2014-15.
S.NO Particulars Expenses (Rs)
1 Cost of raw material in stock as on 01.04.14 25,000
2 Raw material purchased 40,000
3 Direct labour cost 14,000
4 Direct expenses 1,000
5 Factory/work overheads 9,750
6 Administrative expenditure 6,500
7 Selling and distribution expenses 3,250
8 Number of items produced 650
9 Cost of raw material in stock as on 31.03.15 15,000
Net profit of the items is 10% of the total cost of the product.(16)
6) (i) Explain the procedure involved in cost estimation.(8)
(ii) Briefly discuss about most commonly used methods of costing.(8)

7) 200 pieces of a components as shown in fig. are to be drop forged from a 4cm diameter
stock bar. Calculate the cost of manufacturer, if
(i) Material cost is Rs.500 per metre.
(ii) Forging charges @Rs 1000/m2 of surface area to be forged.
(iii) On cost is 10% of material cost. Consider all possible losses during operations.(16
marks)

8) What is the material cost of welding two plates of size 300mm length and 150mm width
and 8mm thickness is make a piece 300x300 approximately. Use rightward technique with no
edge preparation cost. Take overall cost of oxygen as Rs.15/m3,cost of acetylene at
Rs.60/m3cost of filler metal Rs.50 per kg and 1cu.cm of filler metal weighs 11.28gms.
assume dia of filler rod = 4mm. Filler rod used per meter of weld = 3.4m. Rate of welding =
2.1 meter/hour. Consumption of oxygen = consumption of acetylene = 7.1 cu.meter/hr. (16
marks)
9) Calculate the machining time required to produce one piece of the component shown in fig
starting from 25mm bar

The following data is available

For turning: Cutting speed = 40m/min
Feed = 0.4mm/rev
Depth of cut = 2.5mm per pass
For thread cutting: Cutting speed = 8m/min (16 marks)
10) A T-slot is to be cut in a C.I. slab as shown in fig. Estimate the machining time. Take
cutting speed 25m/min, feed is 0.25mm/rev, Diameter of the cutter for channel milling is
80mm (16marks)

END
1) 200 pieces of a components as shown in fig. are to be drop forged from a 4cm diameter
stock bar. Calculate the cost of manufacturer, if
(i) Material cost is Rs.500 per metre.
(ii) Forging charges @Rs 1000/m2 of surface area to be forged.
(iii) On cost is 10% of material cost. Consider all possible losses during operations.(16
marks)

2) What is the material cost of welding two plates of size 300mm length and 150mm width
and 8mm thickness is make a piece 300x300 approximately. Use rightward technique with no
edge preparation cost. Take overall cost of oxygen as Rs.15/m3,cost of acetylene at
Rs.60/m3cost of filler metal Rs.50 per kg and 1cu.cm of filler metal weighs 11.28gms.
assume dia of filler rod = 4mm. Filler rod used per meter of weld = 3.4m. Rate of welding =
2.1 meter/hour. Consumption of oxygen = consumption of acetylene = 7.1cu.meter/hr. (16
marks)
3) A lap joint is to prepared in 9.5mm M.S. sheet using flat welding position and 6mm
electrode. Current used is 250ampere and voltage is 30V. Welding speed is 12meters per hour
and 0.3 kg of metal is deposited per meter length of joint.
Labour costs Rs. 40 per hour, power Rs 8 per KWhr and electrode Rs 55 per kg. Efficiency
of machine is 50% and operating factor is 60%. Calculate the cost of labour, power and
electrode per metre of weld. (16 marks)
4) Estimate the total cost of 20C.I. flanged pipe casting shown in fig. Assume the following
data:
Cost of C.I = Rs30/kg; Cost of process scrap = Rs.7/kg; process scrap = 2% of net weight of
casting; Moulding and pouring charges = Rs.15/piece; Casting removal and cleaning =
Rs.5/piece; Administrative overheads = 5% factory cost; Selling overheads = 70%
administrative overheads.
5) 20 members of gun metal bevel gear blank shown in fig are to