UNIT IV

PRODUCTION COST ESTIMATION

1. Define Forging
Forging is defined as the process in which the desired shape and size of an object is
obtained through the plastic deformation of the metal of the object.
2. Mention the types of forging
Forging may be classified as Hot forging and cold forging.
3. Define upsetting
Upsetting is the process of increasing the thickness or cross section area of the
workpiece by reducing its length.
4. Define Swaging
Swaging is the process of removing the irregularities on the surface of the workpiece
produced by the process of drawing down.
5. Mention the types of weld joints
1. Butt joint 2. Lap joint 3. T joint 4. Edge joint
6. What is gas welding?
Gas welding is the process of joining two metals pieces by a gas flame obtained by
the combustion of fuel gas and oxygen. It comes under a fusion or non pressure
welding process.
7. List the types of welding techniques
1. Forward or leftward technique 2. Backward or Right ward technique
8. Define foundry
Foundry is the process of casting metals in to objects of specified shapes.
9. What are the various allowances in foundry process?
1.
2.
3.
4.
5.
10.
1.
2.
3.
4.

Contraction allowance
Draft allowance
Machining allowance
Distortion allowance
Shake allowance
Mention the elements of foundry cost
Material cost
Labour cost
Direct expenses
Overhead expenses
UNIT V
MACHININIG TIME CALCULATION

1. Define machining time

It is the time for which the machine works on the component i.e., from the time when
the tool touches the work to when the tool leaves the component after completion of
the workpiece.
2. List the terms used in study of machining time
1. Feed
2. Depth of cut
3. Speed
4. Length of cut
3. Define chamfering
Chamfering is the operation of removing material from the edges of external or
internal diameters.
4. Define Facing
Facing is the process of removing material from the ends of the job by moving the tool
perpendicular to the axis of the job.
5. Define Knurling
Knurling is the operation of upsetting material so as to produce diamond shaped or
straight lined patterns on the surface of the material.
6. Define Reaming
Reaming is the process of removing a small amount of material from a previously
drilled or bored hole for perfecting the hole.
7. Define tapping
Tapping is the operation of cutting internal threads with the help of a tool called tap.
8. Define threading
Threading is the process of removing material to produce helix on external or internal
circular surface for fastening purposes.
9. Define Grinding
Grinding is the process of metal removal by abrasion.The grinding machine employs a
multipoint cutting tool called grinding wheel.
10.
What are the methods of grinding
1. Surface grinding 2. Cylindrical grinding

UNIT V
PART-A
1.
2.
3.
4.

What are the methods of grinding ?

Define threading
List the terms used in study of machining time
Define machining time

5. Define Knurling
PART-B
1. Estimate the total time taken to turn a 15cm long 2.5cm dia mild steel rod to a dia
of 2.3cm in a single
Cut. Take cutting speed as 30 m/min. feed 0.1 mm/rev and the mounting time in a
self centering 3-jaw
Chuck as 45 sec.Neglect time taken for setting up tools.
2. A 150mm thick laminated plate consists of 90mm thick steel plate and 60mm thick
brass plate. A 20mm
Dia hole is to be drilled through this plate.Estimate the total time taken for drilling
if
Cutting
Cutting
Feed of
Feed of

speed for steel = 25 m/min

speed for brass = 50 m/min
20mm drill for steel = 0.2 mm/rev
20mm drill for brass = 0.25 mm/rev

3. An operator is required to tap a hole with 20 mm dia tap to a length of 35mm

having 3 threads/cm. The
Cutting speed is 10m/min and number of cuts required are 4. The return speed of
the tap is to be 3
Times the cutting speed.How much time will be taken to cut this internal thread.
4.A 3cm deep slot is to be milled with a 8cm dia cutter.The length of the slot is
30cm.What will be the total
table travel to complete the cut.If the cutting speed is 20 m/min and feed per tooth
is 0.2mm.Estimate the milling time. The cutter has 24 teeth and one cut is sufficient
for the slot.