The Institution of Engineers,India 2008 A.M.I.E Section A Fundamentals of Design and Manufacturing - Question Paper

SUMMER 2008: AN 201/AD 301
FUNDEMENTALS OF DESIGN AND MANUFACTURING
Time : 3 Hours
Maximum Marks :100
ans 5 questions, taking ANY 1 from Group A,
ANY 2 from Group B and ALL from Group C.
ans should be brief and to-the-point and be supplemented with
neat sketches. Unnecessary long answers may outcome in loss of marks.

Figure on the right hand side margin shows full marks.

GROUP A
1.(a) Draw a flow chart showing various stages of engineering design. discuss why stages are
repeated several time. (8 Marks)
(b) How will you integrate the functions of design and manufacturing? How will it help in achieving economic manufacturing (6M)
(c) Differentiate ranging from standardization and specification giving improper examples. (6 mark)
2.(a) discuss in brief (i) robust design, and (ii) role of brainstorming in design idea generation. (3+3 mark)
(b) define the terms ‘economic feasibility’, ‘recyclability’, and ‘evaluation of design’.(2+2+2M)(c) What do you understand by ‘reliability’ and why is it considered? elaborate 3 categories
of failures? Illustrate graphically number of failures vs.time. (8 mark)
3.(a) How will you check the design for clarity, simplicity and safety? Also, discuss how design
is organized and communicated (10M)
(b) Compare the reliabilities of system with components in series vs. components in parallel. Ina system, there are 10 components in series, every with a reliability factor of 0.95. What is the overall reliability of the system? If every of the10 components is in parallel and has individual factor of 0.30 only, what is the system reliability? (10M)
4.(a) How are dissolved gases removed from castings? List 4 castings? List 4 casting
defects. (6 mark)
(b) With the help of neat sketches, discuss extrusion and drawing processes. (6mark)
(c) Compare the cast and forged products of the identical geometry from the view points of strength and quality. (6 mark)
(d)What is the effect of lubrication on die (tool) life during drawing operation? (2mark)


Group B

5.(a) Classify the machining processes. Name the operations which can be performed on a lathe
machine (8 mark)
(b) Differentiate ranging from the shaper and planner. (6M)
c) What do you mean by arc welding? What precautions should be taken during welding? (6 mark)
6.(a) compute the cutting time for cutting 150 mm long keyway using HSS end mill of 20 mm diameter having 4 cutting speed is 38m/min. presume approach and over-travel distance as half of the diameter of the cutter and depth of 4.2 mm can be cut in 1 pass (10 M)
(b) On what basis parts are grouped into families in Group Technology (GT) ? explain with
examples. elaborate the benefits of GT over the conventional setup? (10 M)
7.(a) What is design for manufacturability? How can it be realized in practice? discuss with an
example. (10 M)
(b) What do you mean by unconventional machining process? Why are these processes
necessary? Explain (6 M)
(c) discuss briefly info technology and its elements. (4 M)
8.(a) explain the applications of subsequent in the field of engineering:
(i) Sensors, (ii) robots, (iii) Controller. (iv) AGVs, and (v) AS/RS. (15M)
(b) What is computer Aided process planning (CAPP)? How is it superior to manual process
planning? (5M)

Group C

9.(A) discuss the subsequent in brief: (5×2M)
(i) Tool signature (ii) Data Base Management System (DBMS)
(iii)Hot and cold working of metals
(iv) Modelling vs Simulation
(v) Soft information
(B) State whether the subsequent statements are actual or false:
(i) Moulding is carried out in moulding boxes called flasks. (ii) Taper turning means to produce a conical surface by gradual reduction in diameter from a cylindrical work piece
iii) Laser beam machining is an unconventional machining process.
(iv) Capstan lathe is never used on smaller work.
(v) Sand mould is an example of permanent mould.
(vi) Welding does not permit any freedom in design.
(vii) Discontinuous chips are usually produced while cutting more brittle materials.
(viii) The size of the shaper or planer is specified by the maximum length of stroke.
(ix) Non-conductive materials can be machined by ECM process.
(x) In case of USM, the metal removal cost is low.

Earning:   Approval pending.