Postal Book Package GATE 2022 + PSUs 2022 PRODUCTION AND INDUSTRIAL ENGINEERING Manufacturing Process-Il Co) Sra Mae aCe Icy Contents . Topic fachine Too's Page No. 4. Abrasi 168 & Hole Making Processes % 5. Metal Cuttin 55 6. Non-Tr 7. Advances re MADE EASYManufacturing Process-II Non-Traditional Machines Tras Qa as a4 as ae a7 Which ofthe following processes use mechanical energy as the principal energy source? {@) Electro Chemical Grinding (6) Ulteasonic Machining (©) Laser Beam Machining (@) Electrochemical Machining USM has good machining performance for (@) Al (b) Steel (@) Superalloys (d) Refractory material During ultrasonic machining, the metal removal is achieved by {@) High frequency eddy currents (b) High frequency sound waves (¢) Hammering action of abrasive particios (@) Rubbing action between tool and workpiece Which one of the following is closest to the temperature used in plasma arc cutting, (@) ss00°C (b) 300°C (c) 1000°C (a) 16500°C ‘The mechanism of material removal in EDM process is {@) Melting and Evaporation (b) Melting and Corrosion (©) Etosion and Cavitation (@) Cavitation and Evaporation The primary mechanism of material removal in Electrochemical Machining (ECM) is (a) Chemical corrosion (b) Etching (©) Ionic dissolution (d) Spark erosion The process utilizing mainly thermal energy for removing material is (a) Uttasonic Machining (6) Electrochemical Machining (6) Abrasive Jet Machining (@) Laser Beam Machining ae ag ato atz n Abrasive Jet Machining process, the main mechanism of material removal takes place due to (@) Electrochemical action (b) Mechanical impact (6) Fatigue failure of the material (d) Sparking on impact Which one of the following processes does not cause tool wear? (@) Ultrasonic machining (b) Electric discharge machining (©) Electrochemical machining (a) Anode mechanical machining Which one of the following properties of work materials is responsible for the material removal rate in ECM? (@) Hardness (0) Atomic weight () Thermal conductivity (@) Ductilty Which one of the following statements is correct, in respect of unconventional machining processes? (@) The cutting tools in direct contact with the job. (b) The tool material needs to be harder than the job material. (@) The tool is never in contact with the job. (d) There has to be a relative motion between the tool and the job Chemical Miling is used in which of the folowing applications (@) Drilling holes with high depth to diameter ratio (b) Making intricate patterns in thin sheet metal (©) Removing material from aircratt wing panels (d) Cutting of plastic sheets98 as a4 as a6 a7 ais ag Production & Industrial Engineering Etch factor is equal to which of the following in chemical machining @ cr to) 4 u o 4 (a) None of the above (where C= specific removal rate, d = depth of cut, J = current, t= time and u= undercut) n abrasive jet machining as the distance between the nozzle tip and the work surface increases, the material removal rate, (@) Increases continuously (b) Decreases continuously (©) Decreases, becomes stable, and then increases (@) Increases, becomes stable and then decreases Material used for making a nozzle employed in AJM process may be (@) Copper (©) Sapphire (c) Tungsten Carbide (a) Both (b) andl (c) Inan AJM process, if @ d= Mean diameter of the abrasives, v = Velocity of abrasive particle jet, then MRR is w rate of abrasives, proportional t (@) are (b) ach fe) ace (a) act ‘The number of impacts (in USM) on the workpiece is {@) Directly proportional to the square of the diameter of the grit (b) Inversely proportional to the grit diameter (6) Inversely proportional to the square of the grit diameter (d) None of these For maximum power delivery through the circuit during EDM, ratio of the breakdown voltage to supply voltage is, (@) 0.72 () 10 (©) 075 (@) 065 Which of the following process provide the maximum material removal rato? (@) Electrochemical Machining (ECM) (©) Electron Beam Machining (EBM) () Laser Beam Machining (LBM) (@) Electric Discharge Machining (EDM) Set Q.20 a2 a2 23 a2 Q.25 a.26 Publications During AJM, the mixing ratio used is 0.2 Calculate the mass ratio if the ratio of abrasive density and density of carrier gas is equal to 20. (@ 08 (b) 1.0 (©) 090 (@) 06 In AJM, diameter of the nozzle is 1 mm and jet velocity is 200 m/sec. Determine the volumetric flow rate (in cm/sec) of the cartier gas and abrasive mixture (Va, 9) (@) 100% (b) 50m (©) 500%, (@) 1000 Calculate the material removal (in mm/min) rate in AJM of a brittle material with flow strength of 4 GPa, The abrasive flow rate is 2 grimin and density ofthe abrasive is 3 gnviem®. (Jel velocity is 200 m/sec) In AJM, material removal rate is 0.5 mm*/sec Calculate the material removal per impact (in um®) if mass flow rate of abrasive is 8 gmmin, density is 3 gmicm? and grit size is 50 um. During WuM (Water Jet Machining), the water pressure is 4000 bar, being issued from an otiice of diameter 0.3 mm, Determine the water jet velocity (in m/sec). Assume no losses. (@) 894 (b) 1000 (©) 632 (@) None of the above In electrochemical machining of pure iron, a material removal rate of 600 mm/min isrequired Follwoing data is given Atomic weight of ron = 56 Valeney of iron = 2 Density of iron = 7.8 grvem® Faraday’s constant = 96500 coulomb Determine the current required (in A) in the process During the ECM of iron (atomic weight = 56 valency =2) at current of 1000 A with 80% current efficiency, the material removal rate w as observed tobe 0.26 cm*sec. If Titanium (atomic weight = 48, valency = 3) is machined by the ECM process at the current of 2000 A with 20% current efficiency, the expected material removal rate (in gm/sec) will be (@) 0.14 (b) 028 (©) 030 (@) 082a27 a28 azo 30 ast as2 Set In ECM operation of pure iron (atomic weight = 65.85, valency = 2, density = 7.8 gm/ em) an equilibrium gap of 2mm is to be kept. Determine the supply voltage (in V) if the total over-voltage is 2.5 V. The resistivity of the electrolyte is 50.&-mm and the set feed rate is 0.25 mmimin. In EDM, RC-type generator is used and the maximum charging voltage is 80 V and the charging capacitor is 100 ur. Determine spark energy (in J) In EDM, ifn a RG type generators used, to get an idle time of 500 ps for open circuit voltage of 100 V and maximum charging voltage of 70 V. Determine the charging resistance (in 2). Assume C= 100 nF, InEDM, fora RC type generator to get maximum power dissipation during charging /,= V, x 0.716. Determine the idle time (in ms) for R, = 10.@ and C = 200 pF. In EDM process, determine discharge ti ms) if V, = 100 Volts and Vj = 1500 Volts. Spark energy = 0.5 J. Generator is expected for maximum power during charging. Machine resistance = 0.5 Q 1 (in A resistance capacitance relaxation circuit is used in an EDM process. The discharge voltage is 100 V. Ata spark cycle time of 25 usec, the average power input required is 1 KW. The capacitance (in uF) in the circuits (@) 25 (©) 50 (©) 75 (a) 10.0 Piteroeesk ne) a.33 a4 Which of the following is/are the limitation of Electric Discharge Machining (EDM) (@) Machining of conducting material only (b) Machining of conducting and polymer materials only (c) Lowmaterial removal rate (a) Moderate material removal rate Consider the following statements with reference to Election beam machining and choose the correct statements, (@) The mechanics of material removals meting vaporization a.35 a.36 37 Manufacturing Process-Il Objective Practice Sets | 99 (b) This method can be applied to all materials (©) This method can be used for drilling fine holes (d) This method has very low specific energy consumption The composition (% by weight) off all allay is given below LS 5 & os|ias| 75 [14 | o4| 16] oa The grams atomic weight, are gives below NLS[PRl aS [Mo valency and density Gram atome |58.71/51.09/55.85, 47.9|28.09154.94 63.57 weight (ers) vaeny = [2 |2f2)si4f2/4 Densiyigiom’|e.c0 |7.19 |7.88 | 451/293 |7.43 |.96 If a current of 1500 amps is passed in the ECM process of above alloy, then choose the correct option’s (@) The material removal rate is 3.0584 x 10" em? amps sec (b) The material removal rate is 3.158 em?/min (©) The equivalent density of alloy is 8.28 gicm? (@) The equivalent density of alloy is 9.83 gicm?® ‘An electric discharge machining using a Resistance Capacitance relaxation circuit, if charging time is 250 1 secs for an open circuit voltage of 110 Vand maximum charging voltage of 50 V. If spark time is 50 m secs, then choose the correct option/s (assume capacitance of 100 uf) (@) The value of resistances used in the circuit is 4.1250 (b) Energy released per spark is 0.125 J (@) The average value of power delivered is At7 watts (d) The time constant for the circuit is 4.125 x 104 secs In Laser beam Machining the important process parameters that affects the machining process are (@) Power intensity of lase beam (b) Focused diameter of laser beam (©) Melting temperature of workpiece material (d) Vacuum chamber100] EEEEEE Non-traai 1 10. 19. 28, 36, Production & Industrial Engineering [GATE 2022 + PSUs 2022 nal Machines & 2@ 8 4.) 5. (a) 6. ) 11.) 12 1%) 14. 15. (@) 20, (a) 21. (0) 22. (48) 28. (1960) 24, (0:32) 29. (6.01) 80. (1.58) 31. (1.99) 32. (b) 38. (a,b, 0, ¢) 87. (a.b.c} [ESERIES (Non-Traditional Machines ) USM is a mechanical type non-traditional machining process. In USM, materia is removed by the abrasive grains which are driven to the work surface by a tool oscillating normal to the work surface. (@ Ultrasonic machining is used to machine refractory materials. © In USM, metal is removed by hammering action of abrasive particles on the workpiece. @ Plasma Arc Culting (PAC) uses a plasma stream operation attemperaturesin the range 10,000°C to 14,000°C to cut metal by meting. @) EDMis a thermoelectric process in which heat energy of a spark is used to remove material from the workpiece. The spark energyis capable of partly melting and partly vaporizing material from localized area on the both electrodes, i.e. workpiece and tool, © In ECM, electrical energy is used for material removal along with chemical reaction, Material is removed by depleting operation or anodic dissolution of workpiece. (a) Machining by laser beam is achieved through thermo-optic interaction between the beam and MADE EASY ©) 7. (a) 8. (b) 9. (0) (@) 16. (©) 17. (©) 18. (a) (@) 28. (2688) 26. 27. (13.7) 84. (a,b,c) 85.(a, b,c) work material, Following phases are involved in LBM (Interaction of laser beam with work material () Heat conduction and temperature rise (ii) Melting, vaporization and ablation (b) Abrasive particles mechanically impact the work surface, they fracture off other particles also. ‘As the particles mechanically impacts the surface, it causes a small fracture in the workpiece, and the gas stream carties both the abrasive particles and the fractured (wear) particles away. ) Electrochemical machining does not cause tool wear. ) Ineo, MRR - ME whee = Currenteficeney T= Current E = Chemical equivalent weight . Atomic Weight Valency > rr = UA Fxz = MRR@A © In non-conventional machining, tool is never in contact with the job.Set [GATE 2022 + PSUs 2022 MADE EASY 2 This process is referred as the “chem-mil process. Today, chemical milling is largely used in the aircraft industry, to remove material from aircraft wing Ea Inchemical machining, Etch Factor = 4 a where u= undercut d = depth of cut Ee @ 4 [soon MRR Workpece 30D (Stand OF Distance) ‘As we increase SODNTD (nozzle tip distance), material removal rate increases but after certain SOD, itis not possible to remove work material i.e., MRR decreases. Ea ‘The AJM nozzle is usually made of tungsten carbide or sapphire which has high resistance towear. Ea In an AJM process, MRR & QdP yi? @ InUSM, numberof impacts (N) onthe workpiece by the grits in each cycle will depend upon the number of gits beneath the too! at any ‘ime This is inversely proportional othe diameter of the grt (assumed spherical) 1 Ne where, d = diameter of the grit Manufacturing Process-Il Objective Practice Sets | 101 El In EDM, for maximum power delivery orev, Breakdown voltage where Power, Ws Voltage, Vols El Order for MRR ECM > EDM > EBM > LBM Process. MaximumMRR ECM = 10x 10° mmtimin EDM = 5x 10% mm*imin EBM = 10mm%imin LBM = 5 mmimin Ege We know that, in AJM Mixing Ratio, M= 0.2 = Yo Volumetric flow rate of alsrasive particle Volumetric flow rate of carrier gas Pa — 29 Py Now, Mass rato, Given :102 Production & Industrial Engineering (b) Given: D=1tmm=0.1em v= 200m/sec = v= 200x 10? cm/sec Now, cross-sectional area ofthe nozzle, pe = Zo." Asa = = (0.1" cm? Er) = FO.4F Volumetric flow rate Wag) = AV Rose 2 em) = 7% (0.1? «200% 10" omi/see = 50nem*isec Vag (4s) In AJM, MRR for brittle material can be expressed as are Reg = Te eget where, m, = Abrasive mass flow rate V = Abrasive jet velocity p, = Density of abrasive particle H = Work hardness 2x10°).. oop? 60 Re = to00)"* x(a xto8* (3000)"* x (4 x 10°) = 8x 10" mYsec = 8x 10-1 x 60 mm/min = MRR, = 48mm?/min (1960) Given: MRR = 0.5mm*/sec 3 60 = 8.gmlem® = 8000 kg/m? d, = 50x 10m Now, Number of impacts by abrasive grits per second ma, = 8 gimin = kglsec Set tty Mass of a grt i N og Bio 3x1o% = N 60. x (60x 10")? x:3000 = N= 254,777/sec Material removal perimpact MRR 0.5 mm*/sec N ~ 254.777/sec 96 x 10 mmé 4960 pm? _ [exe _ [2x 4000x108 Py 000 294.4my/seo Ee @ ES ess) ver MRR = 600mm?/min A= 86, 2=2,p =7.8 gmicm* F = 96500 coulomb Now, MRR = —/A_ " ~ FxpxZ _, 8020x107 om? 1x56 Ose 96500 7.82 = 1= 268.8 Ege InEOM MA MRA (in em*/see) = MA (nem*tsen) = OS 0:90 1000 x 56 0.26 = > 96500 px 2 = p = 0.9956 gm/em* Now, MRA ay (in g/sec) _ MA Fxz _ 9.90 x 2000 x 48 ~ 96500 x3 0.290 gmiseccer MADE EASY 13.7) EG 58) Manufacturing Process-Il ObjectivePractice Sets | 103 inecm, y,= © “A.C f Me where Yq = equilibrium gap ning 7 = feed rate C= constant _ 719 200% 10" 5 co. WANNA nr 27106) RipZ Ve where V= supply voltage = 1.58 x 10° sec A = atomic weight => 58ms. AV = over voltage R = Resistivity 99) Z = Valency In EDM, for maximum power during charging, So C= (V2.5) x 55.85 Vt = O.716V, = 0.716 x 100 O80 x 96500 x 7.8 x 10% x2 = Vo= 71.6 v25) Spark Energy, 1347.7 Joy oss (% -2. °) 2 om 3 2 813477 5 on 2x05 Now 2 ( 2) mer 60 = C= 195.06 uF - Given 500V oe 1247.7 “RC Now, Z 1 > 2 vy > V=(11.2+25)volt > Ve 18.7 volt -0.5 x 195,06 x 10% 716 0. In(t- El 02 of a) Given: C= 100x 10°F V=80V = ty = 1994.47 x 10 sec = {y= 199% 10 sec = t= 1.99ms = 6) Work Powe EE 00 ower = oe 4 Ree 1 or { *) 3" nf 1 Ye Pp ve > t 6 R, x100 x 10% 2 > 500x108 = 00x10 = 1000 = 1. Oxo" ol rn) 2" B5x10° 100 > C=5x 10°F > = 6.019 = C= 5pFProduction & Industrial Engineering e & ao (a) & (c) are limitation of EDM. (abe) consumption (a,b, <) Man, q= 0:1035x108 (1 om > (4) ampsec A where, p= 102 quivalent density jensity of component 100 705 185, 75 89 7.19" 7.86 = 8.2256 gf O4 16 | 04 2.33°7.43' 8.96 om? 0.1035 x10? 8.2256 1 = |TOSKe 185K? _TExe, TaxS 58.71” 51.99 5585” 47.9 4x4 | 1.6%2 | 0.1x1 28.08 * 54.94 * 6357 Q = 3.5084 x 10° cm? amp sec 3.5084 x 10° x 1500 x 60 em*4min 158 om*/min Set This method has very high specific energy MADE EASY ES apca ain 250 x 10° = Rx 100 x 10° 250 = Rx 100 x 0.6061 Re 4.124 Joy Energy released per spark, E= 5 CVj 1 3% 100%0.6061 1254 E ‘Average power delivered = 7-7 0.125 (@0+50)x10* = 416.67 watts time constant Ax C = 4.124 x 100 x 10 = 4.124 x 104 sec (abe) (@),(b) and (e) are important process parameters as vacuum is not used in laser beam machining