Production Engi...

A 20 mm diameter hole to be drilled in a sheet at thickness 60 mm. The drill rpm & feed were found to be 600 & 0.3 mm/rev respectively. The drill bit has a point angle of 118°. Assuming 3 mm clearance at approach & exit find the total drill time (in second)

A butt weld joint is developed using plates of thickness 8 mm and GTAW. The welding voltage and current are 24 V and 480 A respectively. If the weld speed is 20 mm/min and the heat transfer efficiency is 86 %, then the heat input per unit length is _______ kJ/mm.

In an extrusion process, a ram of 60 m² area is moving at speed (velocity of ram) 0.02 m/s calculate the velocity (m/s) of extruded material given that die opening area is 2.2 m²

Using the following data obtained from an electrochemical machining (ECM) operation, find the current required (A)

Four parts with the following dimensions are to be assembled in random. What should be tolerance on the assembled length?

\({\rm{Part\;}}1 = 25.32_{ - 0.01}^{ + 0.02}{\rm{mm}}\)

Part 2 = 18.91 ± 0.03 mm

\({\rm{Part\;}}3 = 62.17_{ - 0.01}^{ + 0.05}{\rm{mm}}\)

Part 4 = 46.25 ± 0.04 mm

A sheet metal operation is performed on a sheet of 2.5 mm thickness. Determine the die and punch sizes in the following operations? Assume the clearance to be 2% of thickness.

Calculate true strain in open die forging, as disc of diameter 400 mm and height 180 mm is compressed without any barrelling effect, the final height of disc is 100 mm.

In a metal cutting process, the tool changing time is 12 minutes and the re-grinding cost is Rs. 1/minute, and machining cost is Rs. 0.3/minute. Given that n = 0.3 and c = 200, the cutting speed (in m/min) for maximum productivity is

A drill bit is positioned in absolute system at A (2.5, 1.2) and it has to move to point B (12.5, 24.2). In CNC program, the coordinates of B in an incremental system will be:

In a single – pass rolling operation, a 200 mm wide metallic strip is rolled from a thickness 10 mm to a thickness 6 mm. The roll radius is 100 mm and it rotates at 200 rpm. The roll – strip contact length is a function of roll radius and, initial and final thickness of the strip. If the average flow stress in plane strain of the strip material in the roll gap is 500 MPa, the roll separating force (in kN) is _______

In an arc welding process, two weld coupons were made using two different welding processes. For the first coupon, the voltage, current and welding speed used are 15 V, 300 A and 30 mm/min respectively. Whereas the second coupon is welded with 60 kV, 200 mA and 25 mm/s. If the heat transfer efficiency for welding the first coupon is half of that of the second coupon, the ratio of heat input per unit length is?

For machining a piece of metal, the tool life varies according to speed of cutting and is given as follows:

Then, the total life exponent (n) and constant (c) will be respectively

A gating system has to be designed to fill a mold of dimensions 80 cm × 50 cm × 20 cm. Due to the space constraint, height of the sprue is limited to 15 cm. The filling time should not exceed 30 sec. An engineer gave the sprue dimensions based on the above criteria, but he didn’t consider the gating ratio which is 2 : 1 : 2

Following data is obtained from an orthogonal metal cutting process.

Chip thickness – 0.7 mm, Undeformed thickness – 0.5 mm, Rake angle = 14°, Cutting speed = 3 m/s

Calculate energy required (N.m) in punching press. Given that diameter of blank is 60 mm. Shear strength of material is 260 N/mm². Penetration is 30% and thickness of sheet metal is 2 mm.

To reduce a sheet of thickness 50 mm and width 150 mm to a thickness of 30 mm, two rollers of radius 400 mm should operate at coulomb friction condition. If the yield stress of the sheet material is 200 MPa, then

During orthogonal machining of a mild steel specimen with a cutting tool of zero rake angle, the following data is obtained:

Uncut chip thickness = 0.25 mm

Chip thickness = 0.75 mm

Width of cut = 2.5 mm

Normal force = 950 N

Thrust force = 475 N

The geometry of a tool is given as 8 – 11 – 8 – 6 – 7 – 25 – 1 (ASA). The value of orthogonal rake angle is

A two steel sheets are resistance spot welded with a current of 36,000 A for a period of 0.01 sec. If the effective resistance of the joint be taken as 110 micro ohms, and if the joint can be considered as a cylinder of 6 mm diameter and 2.5 mm in height, take heat required for melting steel as 12 J/mm³ then

A 15 mm diameter rod is reduced to 11 mm by drawing in single pass. Speed of drawing is 100 m/min. Given that semi-die angle is 7°, coefficient of friction between contacting surface is 0.25 calculate power required in drawing in kW. Stress of work material is 450 MPa.