Reg. No.

KSR INSTITUTE FOR ENGINEERING AND TECHNOLOGY, TIRUCHENGODE- 637 215

INTERNAL ASSESSMENT TEST - I
Year/Semester : IV Year / VII Semester Max Marks : 50
Branch : MECHANICAL ENGINEERING Duration : 1 Hour 40 mins
Subject Code & : ME6005 & PROCESS PLANNING AND COST Date & : 20.07.2018 & FN
Title ESTIMATION Session
Answer ALL the questions
PART-A (5 x 2=10)
1. Define the term Process Planning? CO1 K1
2. Write the basic factors to be considered for machine selection? CO1 K1
3. Discuss about the objectives of Process planning? CO1 K2
4. What do you understand by CAPP? CO1 K2
5. What are the main process parameters that can influence the success of the machining? CO2 K2
PART-B (2 x 13=26)
6. a. Explain in detail the process planning activities. CO1 K2
(OR)
6. b.i) List out the factors that are common to both material and process selection. (5 Marks) CO1 K1
6. b.ii) List and explain the various factors considered for tooling selection. (8 Marks) CO1 K1
7. a. Explain the components of retrieval type CAPP System with a block diagram. CO1 K2
(OR)
7. b.i) Describe material selection parameters. (3 Marks) CO1 K1
7. b.ii) Decide the technological framework of process planning by using a block diagram.(10Marks) CO1 K3
PART-C (1 x 14=14)
8. a.i) Compare and contrast between Jigs and Fixtures. (6 Marks) CO2 K4
8. a.ii) Explain the various principles of Jigs and Fixtures design. (8 Marks) CO2 K2
(OR)
8. b.i) A mildsteel component shown in figure below, has to be made from a stock of 220 mm long and calculate CO2 K4
the maximum cutting speed for :
a) Facing operation (2 Marks)
b) Turning operation of all surfaces (2 Marks)
c) Parting off operation (2 Marks)
The maximum spindle speed of the lathe being used is 500rpm.
8. b.ii) List out the basic factors that are to be considered during selection of cutting speed.(8 Marks) CO2 K1

CO1 Explain the concepts and methods of process planning.

CO2 Discuss the process planning Activities.

K1: Remembering K2: Understanding K3: Applying K4: Analyzing K5: Evaluating K6: Creating
% of Remembering % of Understanding % of Application and higher order Abilities (K3+K4+K5+K6) Total
31.11% 44.44% 24.45% 100%

Course Instructor Course Coordinator Module Coordinator Programme Coordinator

 Reg. No.

KSR INSTITUTE FOR ENGINEERING AND TECHNOLOGY, TIRUCHENGODE- 637 215

INTERNAL ASSESSMENT TEST-III
Year/Semester/Section : Year/ Semester Max Marks : 70
Branch : B.E- Mechanical Engineering Duration : 2 Hr 30 min
ME6005 – Process Planning and
Subject Code & Title : Date & Session : 12.09.2018 & AN
Cost Estimation
Answer ALL the questions
PART-A (8x 2=16)
1. Write the various losses incurred in forging operations? CO4 K1

2. What do you meant by Left hand and right hand welding? CO4 K2
3. List the various forging processes. CO4 K1
4. Write the procedure to calculate the foundry shop cost estimation? CO4 K1
5. Define “tool approach” and „tool overtravel”. CO5 K1
6. Write the steps involved in cutting time calculation? CO5 K1
7. Define machining time. CO5 K1
8. What are the different allowances provided in the machining time calculations? CO5 K2

PART-B (3 x 13=39)
9. (a) Calculate the net weight and gross weight for the component shown in Fig. Density of material CO4 K3
used is 7.89 gm/cc. Also calculate: (i) Length of 14 mm dia bar required to forge one
component. (ii)Cost of forging/piece. If Material cost = Rs. 100 per kg, Labour cost = Rs. 10 per
piece and Overheads = 150 percent of labour cost.

Or
9. (b)Estimate the cost of a container open on one side of size 0.5 m × 0.5 m × 1 m is to be fabricated CO4 K2
from 6mm thick plates. The plate metal weighs 8 gms/cc. If the joints are to be welded. The
relevant data is : Cost of plate = Rs. 50 per kg, Sheet metal scarp (wastage) = 5 percent of
material, Cost of labour = 10 percent of sheet metal cost, Cost of welding material = Rs. 30 per
meter of weld.
10. (a) What is the total cost of the casting? The following are the details regarding the foundry shop: CO4 K2
A casting weighs 20kg, the weight of the returnable scrap is found to be 8kg. The cost of molten
metal at the cupola spout is Rs. 100 per kg and scrap is valued at Rs.30 per kg.
Time taken by the casting in different processes are.
Shop Time taken Lobour rate On cost rate
Moulding and Pouring 20minutes Rs.50 per hour Rs.6 per hour
Shot blasting 5minutes Rs.40 per hour Rs.5 per hour
Fettling 1minute Rs.30 per hour Rs.2 per hour
 Or
10. (b)
What is the material cost of welding two plates of size 300mm length and 150mm width and CO4 K2
8mm thickness to make a piece of 300 x 300mm aprox. Use rightward welding technique with
no edge preparation cost. Take overall cost of oxygen as Rs.7 per cu.metre, cost of acetylene as
Rs.7.5 per cu.metre, cost of filler metal Rs.25 per kg and 1cu.m of filler metal weighs 11.28gms.
Oxygen consumption = 0.71cu.m / hour, acetylene consumption = 0.71cu.m / hour, dia. of filler
rod 4mm, rate of welding =2.1m/ hr filler rod consumption = 3.4 m.
11. (a) A mild steel bar 100 mm long and 38 mm in diameter is turned to 35 mm dia. and was again CO5 K3
turned to a diameter of 32 mm over a length of 40 mm as shown in the Fig. The bar was
machined at both the ends to give a chamfer of 45° × 5 mm after facing. Calculate the
machining time. Assume cutting speed of 60 m/min and feed 0.4 mm/rev. The depth of cut is not
to exceed 3 mm in any operation.

Or
11. (b) Calculate the machining time to drill four 8 mm dia. holes and one 40 mm dia. centralhole in the CO5 K3
flange shown. 20 mm dia. hole is drilled first and then enlarged to 40 mm hole. Take cutting
speed 10 m/min, feed for 8 mm drill 0.1 mm/rev, for 20 mm drill feed is 0.2 mm/rev. and for 40
mm drill feed is 0.4 mm/rev.

PART-C (1 x 15=15)
12. (a) Find the time required to manufacture the part shown in fig. from mild steel stock of 4cm in dia. CO5 K3
and 6.5cm long. Assume cutting speed for turning and boring is 20meter per min. and for
drilling 30 meter per min. feed for boring and
turning is 0.2mm/rev and for drilling of 20mm drill is
0.23mm/rev.
 Or
12. (b) A T-slot is to be cut in a C.I. slab as shown. Estimate the machining time. Take cutting speed 25 CO5 K3
m/min, feed is 0.25 mm/rev. Dia. of cutter for channel milling is 80 mm.

CO4 Estimate the cost of various products in different production shop.

CO5 Estimate the machining time for various machining processes.

K1: Remembering K2: Understanding K3: Applying K4: Analyzing K5: Evaluating K6: Creating
% of % of % of Application and higher order Abilities
Total
Remembering Understanding (K3+K4+K5+K6)
9.67 34.67 55.66 100

Course Instructor Course Coordinator Module Coordinator Programme Coordinator