ODD

I V Y E A R M E C H A N I C A L E N G I N E R I N G SEMESTER
ME 6005
PROCESS PLANNING AND COST ESTIMATION
UNIT - I
INTRODUCTION TO PROCESS PLANNING
Introduction – methods of process planning – Drawing interpretation – material evaluation – steps in
process selection – production equipment and tooling selection
PART - A
1. What is process planning? (Nov/Dec 2010,17)
(Or)
Define process planning. (Nov/Dec 2015)
2. List any four information required for process planning. (Nov/Dec 2012),(May / Jun 2013,15)
3. What are the advantages of manual process planning? (Nov/Dec 2012)
(Or)
What are the advantages and disadvantages of manual process planning? (Apr/May 2018)
(Or)
What are the details required for process planning ?
4. State the parameters involved in material selection. (Nov/Dec 2014)
5. What are the types of process planning? (May / Jun 2012) (Apr/May 2015,19)
6. Compare manual and computer aided process planning. (Nov/Dec 2009)
7. What are process planning activities (Nov / Dec 2011)
(Or)
What are the activities associated with process planning? (May / Jun 2012)
8. What are the factors considered machine selection? (May / Jun 2013)
9. What is the information that a route sheet can provided? (Model Question paper-1)
10. Compare and contrast the features of variant and generative CAPP systems.
(Or)
Differentiate between variant and generative CAPP systems. (Model Question paper-1)
11. What are the stages of the tool selection process?
12. What are the activities associated with process planning?
13. What factor should be considered for selecting best process planning system?
(Or)
What are the factors to be considered during the selection of a process? (May / Jun 2017)
14. What is CAPP? What are the advantages of CAPP?
15. What are four stages in machine selection?
16. What is manual process planning?
17. State the general approaches to process planning?
18. Study the drawings shown in fig and interpret any one geometric tolerance symbol .

(Or)

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Interpret the symbol (Nov/Dec 2018)

19. List the objectives of process planning. (Nov/Dec 2018)

20. How surface finish is indicated on an engineering drawing. (Apr/May 2019)

PART - B
1. Explain the technological framework of process planning by using a block diagram. (Apr / May 2015)

2. Explain in detail the process planning activities. (Apr/May 10,15) (Nov/Dec 07,10,11,13)
(Or)
List out the objectives of process planning .Explain the various approaches to process planning. (Ap15)
3. Describe the various types of charts and diagrams used in process planning. (Apr / May 2012)
4. What do you understand by CAPP? Explain in detail about the types of CAPP and mention the benefits
of CAPP. (Apr/ May 2008) (Nov/Dec 2012,15)
(Or)
Explain the use of computers in process planning and cost estimation and list out the advantages of
CAPP.(16) (Nov / Dec 2014)
5. What are the procedures to be followed for the machine selection? (Apr/ May 2011)
6. (i)Why is process planning required to estimate cost ? state its advantages .Discuss in detail the
methods how computer can be used in cost estimates . (Apr/May 2018)
(ii) Write note on different methods of process planning. (Apr/May 2018)
7. Explain the basic method employed for the selection of cutting tools. (Nov/Dec 2018)
8. Discuss the production equipment and tool selection for the component shown in fig . Undercut
diameter is 12 mm. (Apr/May 2018)

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UNIT - II
PROCESS PLANNING ACTIVITIES
Process parameters calculation for various production processes – selection jigs and fixtures – election of
quality assurance methods – set of documents for process planning – Economics of process planning –
case studies.
PART - A
1. List the documents required for process planning (Nov / Dec 2010)
(Or)
Enumerate the documents required for process planning (Nov / Dec 2015)
2. State the procedure to select the cost optimal processes (Nov / Dec 2011)
(Or)
Select the procedure to select the cost optimal processes. (Nov / Dec 2011)
3. Define: Under Estimate. (Nov / Dec 2014)
4. Define: Breakeven point. (Nov/Dec 2014)
(Or)
What do you understand by break event analysis? List its objectives.
5. Classify the three basic functions of Jigs and fixtures. (Nov/Dec 2017)
6. List the factors to be considered while selecting process parameters. (Nov/Dec17) (Apr/May 2019)
7. What are the reasons for process documentation?
8. What is meant by feed rate? List the major factors that are to be considered during the selection of feed
rate.
9. Compare and contract jigs and fixtures.
10. Define the term quality and TQM
11. What is the purpose of a work holding device? List the types of work holding device .
12. What is meant by process capability?
13. List the various factors that influence the design / or selection of a work holder.
14. What are the types of jigs and fixtures?
15. What is statistical quality control?

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16. Define process capability
17. What are the objective of inspection
18. What factor should be considered for selecting measuring instruments?
19. What is activity based costing? (Apr/May 2018)
20. What are the elements of costing? (Apr/May 2018)
21. What are the basic principles of design of jigs and fixtures? (Apr/May 2019)
(Or)
What are the main reasons for using jigs and fixtures? (Nov/Dec 2018)
22. Differentiate between Route sheet and Process sheet. (Nov/Dec 2018)

PART - B
1. Describe material selection parameters (8) (Nov/Dec 2007) (Nov / Dec 2010)
(Or)
What are the two distinct approaches used in material selection? Explain the basic steps involved in
both the cases. (Apr/May 2019)
2. Describe the various types of charts, diagrams and other documents used in process planning(16)
(May / Jun 2012) (Nov/Dec 2018)
(Or)
Discuss the following “there are a number of patterns that a process control chart can exhibit that indicate a
process is out of control without any points outside the control limits” (Apr/May 2019)
3. Write the process planning procedure.(8) (May /Jun2013,15)
(Or)
Describe the steps or procedure involved in process planning. (Nov/Dec 2018)
4. What are the factors influencing process selection and write down the process selection parameters.
(16) (Nov / Dec 2014)
(Or)
Discuss the different steps involved in process selection. (Apr/May 2019)
5. List the various types of limit gauges that are being employed for attributes inspection.
(Or)
List and explain the various factors to be considered for selection of measuring instruments
(Nov/Dec 2018)
(Or)
List the measurement instruments that are commonly used for variables inspection.
6. What are the basic elements of jigs and Fixtures?
7. Explain the importance of selection of the right quality assurance method during manufacturing.
(16) (Apr/May 2018)
8. Explain the factors to be considered in selection of process parameters. (16) (Apr/May 2018)
9. Explain six degrees of freedom with a neat sketch. (6) (Nov/Dec 2018)
UNIT - III
INTRODUCTION TO COST ESTIMATION
Importance of costing and estimation – methods of costing – elements of cost estimation – Types of
estimates – Estimating procedure – Estimation of labor cost , material cost – allocation of overhead
charges – calculation of depreciation cost.
PART - A
1. Define costing (Nov / Dec 2010,12) (May / Jun 2013)
(Or)
What do you mean by costing (Nov / Dec 2013)
(Or)
What do you mean by cost accounting? (Nov / Dec 2017)
2. What are the various types of estimates? (Nov / Dec 2010)
(Or)
Enumerate different types of estimates. (Nov / Dec 2015)
3. What is the different classification of costs? (Nov / Dec 2010)

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4. What is right hand (RH) and left hand (LH) welding? (Apr/May 2018)
5. Why is cost estimation used?. (Nov / Dec 2011) (Apr/May 2019)
6. Distinguish between costing and cost estimation. (Nov / Dec 2011,15,18)
7. What do you mean by a realistic estimate? (May / Jun 2012)
8. Define the term ‘Direct material cost’. (May / Jun 2012)
9. What do you mean by overhead expenses? (May / Jun 2012, 15) (Nov / Dec 2014)
10. What do you mean by multiple cost method? (Nov / Dec 2012)
11. Brief about allocation of overheads. (Nov / Dec 2010,18)
12. Mention any two functions of cost estimation. (May / Jun 2013) (Nov / Dec 2013)
13. Write the importance of depreciation. (Nov / Dec 2013)
14. What are the causes of depreciation (Apr/May 2018)
15. How can you calculate the labor cost for a turning process in lathe? (Nov / Dec 2013)
16. What is meant by target cost? (Nov / Dec 2014)
17. What is meant by conceptual cost estimation? (Nov / Dec 2014)
18. Estimate the weight of the component Shown in fig . The material is CI . (Apr/May 2018)

19. What is batch costing? (Apr / May 2015)

20. Brief about the procedure to calculate material cost. (Nov / Dec 2015)
21. Estimate the power cost for melting Aluminum of 150 kg at 650°C from room temperature of 35°C.
Specific and latent heats of Aluminum are 0.91 KJ/kg and 398 KJ/kg respectively . Unit cost of
power is Rs 7 (Apr/May 2018)
22. What is parametric estimating? (Apr/May 2019)
PART - B
1. Explain various types of estimates (12) (Nov / Dec 2010,11)
(Or)
What are the types of estimates? (Nov / Dec 2011)(May / Jun 2012, 13)
(Or)

Describe different method of estimates.(10) (Nov / Dec 2010,11,15)

(Or)
Discuss in detail about the types and methods of estimating. (Apr / May 2008)
(Or)
Enumerate about conceptual cost estimating method (Apr/May 2019)
(Or)
What are the three methods used in conceptual cost estimation? Explain any two methods briefly. (8)
(Nov / Dec 2014)
2. Describe elements of cost in detail.(16) (Nov / Dec 2010)
(Or)
Name the various elements of cost. Explain each element in detail giving suitable examples
(Apr / May 2015)
(Or)
Describe the classification and elements of cost.(16) (Nov / Dec 2015)
(Or)
Discuss various costing methods. (8) (Nov / Dec 2011)(May / Jun 2012,13)
(Or)
Explain the major elements of cost.(8) (Nov / Dec 2010) )(May / Jun 2012,13)
(Or)
Discuss various method of costing n detail. (8) (Nov / Dec 2017)
3. Discuss the sources of data for cost estimation.(6) (Nov / Dec 2010)

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(Or)
Explain the data requirement for estimation.(6) (Nov / Dec 2010)
(Or)
Write the data requirements and sources of information for cost estimation.(8) (Nov / Dec 2014)
(Or)
4. Differentiate between cost estimating and cost accounting.(8) (May / Jun 2012)
(Or)
Differentiate between costing and estimation.(8) (Nov / Dec 2013)
(Or)
Explain the objectives of cost estimating (Apr/May 2019)
5. Briefly discuss the estimating procedure.(8) (May / Jun 2012)
(Or)
Explain the procedure involved in cost estimation. (Apr / May 2015) (Nov / Dec 2011, 14)
6. Describe and compare the various methods of allocation of overhead expenses.(15)
(May / Jun 2012) (Nov / Dec 2012) (Apr / May 2019)
(Or)
Briefly explain the distribution and allocation of overheads. (Apr / May 2010)
(Or)
Discuss the various methods used for allocation of overheads . (Nov / Dec 2017)
(Or)
Discuss about the determination of material and labor cost.(8) (Nov / Dec 2013)
(Or)
Write short notes on : (i) Direct labour cost (ii)Direct material cost (iii)overheads. (Apr / May 2010)
(Or)
List down various items that constitute the overhead expenses. (Apr / May 2009)
(Or)
Explain the process of estimation of material cost , labour cost and overheads . (Apr / May 2012)
(Or)
Explain the procedure followed for estimating the cost of an industrial product.(16)
(Nov / Dec 09 ,12,) (May / Jun 2013)
(Or)
Explain the procedure followed for estimating the cost of an individual product. (8) (Nov / Dec 2017)
7. Calculate the prime cost, factory cost, production cost, total cost and selling price per item from the
data given below for the year 2012-2013.
Cost of raw material in stock as on 01.04.2012 = Rs 25,000
Raw material purchased = Rs 40,000
Direct labour cost = Rs 14,000
Direct expenses = Rs 1,000
Factory/ Work over heads = Rs 9,750
Administrative expenditure = Rs 6,500
Selling and distribution expenses = Rs 3,250
Number of item produced = 650
Cost of raw material in stock as on 31.03.2013
Net profit of the items is 10% of the total cost of the product. = Rs 15,000.
(Or)
A manufacturer is making 100 units of an item per hour and incurs the following expenses:
Direct material cost = Rs 35
Direct labor cost = Rs 200
Direct expenses = Rs 75
Factory on cost = 150 % of labour cost
Office on cost = 30 % of labour cost
Find out the selling price for a profit of 15% on the selling price. (10) (Nov / Dec 2015)
(Or)

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A factory has 25 lathes of same make and capacity and 10 CNC machining centers of same make and
capacity. Lathe occupies 70m2 and CNC machining centers occupies 40m2. The factory expenses are given
below :
DESCRIPTION PERIOD AMOUNT
( Rs)
Building rent and Annual 70,000
depreciation
Direct labour Month 60,000
Indirect labour and Month 5,000
Indirect material
Depreciation charges for Annum 2,00,000
lathes
Depreciation charges for Annum 10,00,00
CNC m/c center
Power consumption for Month 3,50,000
lathe
CNC m/c center for Month 8,50,000
CNC m/c center
Insurance for lathes Annum 25,000
Insurance for CNC m/c Annum 20,000
center
Find out the machine hour rate for lathe and CNC m/c center if they work for 5000 hrs and 3000 hrs
respectively. (Apr/May 2018)
(Or)
An apparel factory has a fork lift truck which is used by receiving and shipping departments. In receiving
section large rolls of fabric are handled while in shipping sections cartons of finished parts are handled.
Fork lift costs are shown in table . Fork lift spends 70% of time in shipping and 30% in receiving .

Operator salary Rs.75,000

Maintenance Rs.15,000
Depreciation Rs.20,000

Others Rs.5000

The factory operates two production lines. One line is for jeans and the other for T shirts . Operational data
per month is given below
jeans T shirts Total
Units produced 5,50,000 3,20,000 8,70,000
Direct labour hrs 90,000 50,000 1,40,000
Rolls of fabric 2250 850 3100
Cartons shipped 60000 25000 85,000
If the total over head of the factory is Rs. 18,50,000, find fork lift expenses per unit of jeans and T shirts.
(Apr/May 2018)
Calculate the selling price per unit from the following data:Direct material cost = Rs 8000 , Direct labour
cost = 60 % of direct cost,Direct expenses = 5% of direct labour cost,Factory expenses = 120% of direct
labour cost, Administrative expenses = 80% of direct labour cost,Sales and distribution expenses = 10% 0f
direct labour cost,Profit = 8% of total cost,Number of pieces produced = 200. (Nov/Dec 2018)

UNIT -IV
PRODUCTION COST ESTIMATION

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Estimation of different types of jobs – Estimation of forging shop, Estimation of Welding shop, Estimation
of Foundry shop
PART - A
1. A production shop had its production overheads of Rs.12, 000/- and the production for the period
in terms of direct labour was 24,000 hours. Find the over head for a job requiring 20 labour hours.
(Nov/Dec 2015)
2. List out the material losses in forging . (Nov/Dec 2014)
(or)
Mention various losses in forging. (Nov/Dec 2013)
(or)
Name the various losses in forging process. (Nov /Dec2017)
3. What are the various elements considered while calculating the cost of a welded joint?(Nov/Dec 2012)
4. Differentiate leftward and rightward welding. (Nov/Dec 2017)
5. Discuss briefly various operations that can be performed by forging.
6. Describe the types of welding.
7. What is the relationship between thickness of plate and size of electrode in gas welding?
8. How can you estimate the gas cutting cost?
9. Define foundry, casting and mould.
10. Name the pattern allowances which can be quantitatively specified. Write brief note on each of them.
11. What is shrinkage allowance? How is it provided for patterns?
12. Why machining allowance is kept in a pattern?
13. What is right hand (RH) and left hand (LH) welding? (Apr/May 2018)
14. List out the various allowances provided to the pattern.
15. A Butt joint between two square metal plates of 250 cm × 250 cm is made using electric arc welding.
If the rate of welding is % Meter /hr , calculate the time required to complete ten such welding
operations .
16. What are the various elements considered while calculating the cost of a welded joint(Apr/May 2010)
17. Give the formula for calculating the cost of power consumed in arc welding. (Nov/Dec 2018)
18. Name the various sections in foundry shop. (Nov/Dec 2018)
19. What is meant by flash loss? (Apr/May 2019)
20. How is cost of material required for casting calculated? (Apr/May 2019)
PART - B
1. A square bar of 3 cm side and 25 cm length is to be hand forged into a hexagonal bar of side of 1.5
cm.Find length of the hexagonal bar ignoring metal losses. Density remains same. (6) (Nov/Dec 2015)
(or)
A bar stock of 30 mm diameter and 2 m long is to be converted to (i) Square bar of 30 mm side; (ii)
Hexagonal bar of 30 mm side; (iii) Rectangular bar of sides 30 mm * 20 mm. Calculate the length of
bar made in each case. Assume hand forging and 2% losses. (Nov/Dec 2013)
(or)

(15) (Apr/May 2018) (Nov/Dec 2018)

2. Determine the selling price of a valve components weighing 500 kg with the following data:
(i) Density of the cast iron material = 7.2 gm/cc

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(ii) Cost of the molten iron at cupola = Rs.25 per kg
(iii) Process scrap = 17% of net weight
(iv) Scrap return value = Rs. 11 per kg
(v) Admin and sales OH = Rs. 50 per piece
(vi) Profit = 10% of total cost
Process Labour Shop OH/hr
Activity
Time/valve(min.) Cost/valve(Rs.) (Rs.)
Molding and
72 26 42.5
pattern making
35
Core making 96 24
Felting and 30
120 27.5
cleaning
(Nov/Dec 2013)
(or)
200 pieces of a component as shown in fig . 1 are to be drop forged from a bar stock of dia 4 cm .Calculate
the cost of manufacturing if (1) Material cost is Rs 1000 /meter , (2) Forging charges are Rs .10 /cm 2 of
surface area to be forged , (3) on – cost is 10 % of material cost .Consider all possible losses .(10)

(Nov/Dec 2017)

(or)
200 MS pins of 4 cm dia and 10 cm length are to be drop forged from a bar of 5 cm diameter. Calculate
material cost taking the cost of stock as Rs. 200 per metre. Consider all the losses. Also calculate the
forging cost assuming the cost of forging as Rs. 1,200/sq.metre of surface area. (12) (Nov/Dec 2010)

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(Apr/May 2019)

3. What are the components of a job estimate? Explain. (16) (May/June 2013,Nov/Dec
2018)
(or)
Discuss the various components of a job estimate. (16) (Nov/Dec 2013)
4. Two 1 m long M.S. plates of 10 mm thickness are to be welded by a lap joint with a 8 mm electrode.
Calculate the cost of welding: (16)
Assume the following data:
(i) Current used = 30 amperes
(ii) Voltage = 300v
(iii) Welding speed = 10 m/hr
(iv) Electrode used = 0.1 kg/m of welding
(v) Labour charges = Rs. 4.00/hr
(vi) Power charge = Rs. 0.2/kwh
(vii) Cost of electrode = Rs. 40.00/kg
(viii) Efficiency of machine = 70% (May/June2013)(Apr/May 2019)
(or)
A platform is made by welding 10 joints of 1 m length each out of 20 mm steel plates. Other data are
as follows: (8)
Labour charges = Rs. 15/hr
Cost of electrode = Rs. 6/meter
Cost of power = Rs. 2/unit
Over heads = Rs. 2.5/hr
Length of electrode per meter run = 2.5m
Power consumption = 6 units per m run
Time for 1 meter run = 1.8 mm
Calculate the cost of welding above platform assuming that welding is done on one side only (Nov 10)
(or)
Find the rate kg for per melting CI in an induction furnace. Furnace operates on 3 shift basis for 300
Working days. Assume depreciation period is 10 years and that the furnace investment is done 100%
Through bank for an interest rate 12% and the repayment period is 10 yrs .
Furnace cost Rs. 60 lakes.
Power 750 kVA with 0.95 power factor . Power cost is Rs.6/month
Labour Rs.20000/month

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Material cost Rs.38/kg
Miscellaneous and consumable expenses Rs. 70,000 per annum.
Maintenance charge Rs 2 lakhes/annum
Specific heat of CI = 0.46 KJ/kg and latent heat 272 KJ/kg
Furnace capacity = 1 ton. (Apr/May 2018)
5. List the various elements which are to be considered while calculating the cost of a welded joint.
(Nov/Dec 2017)
6. State and explain various losses which are to be considered in a foundry shop. (Nov/Dec 2017)
7. Generalize the meaning of tong hold loss in forging. (Nov/Dec 2017)
8. What are the various losses considered while calculating the material cost for a forged component?
Explain. (Nov/Dec 2018)
9.Calculate the total cost of CI (Cast Iron) cap as shown in fig. Cost of molten iron in cupola spout = Rs 30
per kg, Process scrap = 17 percent of net weight of casting Process scrap return value = Rs 5 per kg,
Administrative overhead charges = Rs 2 per kg of metal poured.density of material used = 7.2
grams/cc.The other expenditure details are as below

Process Time per piece (min) Labour charges per hour Shop overheads per hour

Moulding and pouring 10 Rs 30 Rs 30

Casting removal , gate

4 Rs 10 Rs 30
cutting

Fettling and inspection 6 Rs 10 Rs 30

(Nov/Dec 2018)

UNIT – V
MACHINING TIME CALCULATION
Estimation of Machining Time - Importance of Machining time calculation- Calculation of Machining
time for lathe, drilling, Boring, Milling, Shaping , Planning, Grinding.

PART - A
1. Calculate the cutting speed on a job of 50 mm diameter rotating at 200 rpm. (Nov/Dec 2015)
2. Define cutting speed. (May/April 2015)

(or)
What do you mean by cutting speed?

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(or)
Define the term of cutting speed.

(or)
Define cutting speed. List various factors affecting cutting speed . (Nov/Dec 2017)
3. List out the elements of drilling cost estimation. (Nov/Dec 2013)
4. Derive an expression for machining time in planning machine. (Nov/Dec 2011)
5. Derive an expression for estimating time for plain turning in lathe. (Nov/Dec 2010)
6. What are the various losses considered while calculating direct material cost for a casting?
(Apr/May2012) (Apr/May 2015)
7. Differentiate between feed and depth of cut
8. Discuss the various factors for the selection of (a) Cutting speed (ii) Feed and (iii) Depth of cut
9. How can you calculate the turning time required on a lathe?
10. What is length of cut?
11. What are the various factors to be considered for the selection of cutting speed?
12. What is the purpose of chamfering and knurling operations?
13. Estimate the machining time

(or)
What is machining time ?
14. Estimate the machining time to face both ends of a work piece of 30 mm steel rod in one cut ,if the
cutting speed is 30 m/min and cross feed is 02 m/rev .
15. How long it will take a 12.7 mm drill to drill a hole of 80 mm deep in brass plate .Take the cutting
speed as 75 m/min and feed as 0.175 mm/rev .
16. What do you mean ‘tool approach’ and ‘tool over travel’? Show diagrammatically how these terms
are related to the length of cut for a cutting operation.
17. What is mean by depth of cut?
18. Write steps involved in cutting time calculation . (Apr/May 2018)
19. What are the typical data required for cutting time calculation in shaping . (Apr/May 2018)
20. Write short note on tear down time. (Nov/Dec 2018)
21. Find the time required to shape a slot 300mm long,10 mm wide and 5 mm deep in a CI block. Given
that cutting speed is 10m/min, feed 1mm/ stroke and maximum depth of cut as 2.5mm Assume K=0.25
(Nov/Dec 2018)
22. What is meant by interference allowances? (Apr/May 2019)
23. When calculating machining times, allowances are used. Why is it important? (Apr/May 2019)

PART - B
1. A 25 cm * 10 cm C.I.surface is to be faced on a milling machine with a cutter of diameter of 15 cm
and 16 teeth. If the cutting speed and feed are 55 m/min and 6 cm/min respectively. Determine the rpm
of the cutter, feed/tooth and milling time.(8) (Nov/Dec 2015)
(or)
A 80mm diameter plain milling cutter having 6 teeth is used to face mill a block of aluminum 200mm
long and 30mm wide. The spindle is 1500rpm and feed is 0.125mm/teeth/rev. Find the cutting speed.
(8) (Nov/Dec 2013)

2. Find the time required for finish grinding a 20 cm long steel shaft to reduce its diameter from 4.5 cm to
4.3 cm with a grinding wheel of 2.5 cm face width. Cutting speed is 16 m/min and depth of cut is 0.2
mm.(8) (Nov/Dec 2015)
(or)
Find the time required to drill 4 holes in a CI flange each of 2 cm depth, if the hole diameter is 2 cm .
Assume cutting speed as 21.9 m/min and feed as 0.02 cm /rev. (8) (Nov/Dec 2017)
(or)

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A keyway has to be cut in spindle whose dimensions are 46 cm length , 5 cm diameter and 1 cm
width . The cutter diameter is 13.25 cm .If the cutter revolves at 120 rpm , what is the time required to
cut a 1 cm deep at a feed of 0.05 cm /rev of cutter ? (Nov/Dec 2017)
(or)
Determine the time required to rough grind a 25cm shaft of bronze from 40mm diameter to 38mm
diameter using a grinding wheel of 50mm face width. Assume cutting speed as 20m/min and the depth
of cut as 0.2 mm/pass.(8) (Nov/Dec 2013)

3. A 60 mm rod of aluminum to be machined on a lathe, the finished size is shown in figure. The length
of rod is 175 mm. Determine the total machining time and material cost, if material is purchased at the
rate of Rs. 12 per kg. Assuming cutting speed 30 m/min and feed 0.2 mm/rev. Take density of
aluminium as 2.7 gm/cc. Depth of cut not to exceed 2.5 mm.(16) (Apr/May 2015)

(or)
A t-slot is to be cut in a C.I. slab as shown in fig. given below Estimate the machining time. Take
cutting speed 25 m/min, feed is 0.25 mm/rev, Diameter of cutter for channel milling is 80 mm.(16)

(Nov/Dec 2014 ,2018)

(or)

(Apr/May 2018)
(or)

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I V Y E A R M E C H A N I C A L E N G I N E R I N G SEMESTER

(Apr/May 2018)
(or)
Calculate the machining time required to produce on piece of the component shown in fig. given
below starting from f 25 mm bar. The following data is available. (16)
For turning: Cutting speed = 40 m/min
Feed = 0.4 mm/rev
Depth of cut = 2.5mm/pass
For thread cutting: Cutting speed = 8 m/min (Apr/May 2015)

(or)
A mild steel bar 120 mm long and 40 mm diameter is turned to 38 mm dia and was again turned to a dia
of 35 mm over a length of 50 m as shown in fig . The bar chamfered at both the ends to give a chamfer
45 ° × 4 mm after facing . Calculate the machining time .Assume cutting speed of 50 m/min and feed 03
mm /rev .The depth of cut is not to exceed 3 mm in any operation.(16) (Nov 2016) (Nov/Dec 2018)

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I V Y E A R M E C H A N I C A L E N G I N E R I N G SEMESTER

A hole of 15mm dia and 10cm deep is to be drilled through a MS specimen. Estimate the time taken for
drilling in each of the following methods:
(i) Drilling the hole with a 15mm drill
Machining parameters are: cutting speed = 30 m/min.
Feed = 0.2mm/rev.
(ii) Drilling an initial hole of 10mm dia with 10mm drill bit and final enlargement of the hole
to 15mm dia by boring. Machining parameters are:
Cutting speed for drilling = 30 m/min.
Cutting speed for boring = 30 m/min.
Feed for drilling = 0.15 mm/rev.
Feed for boring = 0.12 mm/rev. (8) (Nov/Dec 2011)
4. Describe the procedure of estimating the machining time required during shaping operation on a
shaper. (16) (Apr/May 2015)
(or)
Explain about the estimation of grinding time for a cylindrical grinding operation (8) (Nov/Dec 2013)
(or)
Determine the added table travel in milling operation. (8) (Nov/Dec 2013)
(or)
Elucidate about time elements considered to arrive at total time required to perform a machining
operation. (Nov/Dec 2018)
(or)
Briefly explain the estimation of machining time for various lathe operations with sketches. (16)
(AprMay 2012)
5. What will be the machine time required to rough bore, to second bore and to finish bore a soft cast iron
cylinder whole diameter is 220mm and the length of bore in 260mm.
(i) Rough bore 39rpm, 2.857mm feed
(ii) Second rough bore 45rpm, 0.987mm feed
(iii) Finish bore 25rpm, 5.75mm feed (16) (Nov/Dec 2012)
6. A lap joint is to be made in 9.5mm MS sheet using flat welding position. Current used is 250 Amperes
and the voltage is 30V. Welding speed is 12 m/hr and 0.3 kg of metal is deposited per metre of weld
joint. Labour cost Rs. 15/ hr and the power charges are Rs. 2 / kwh while the electrode cost Rs. 40/kg.
Calculate the cost of labour, power and electrode. Assuming efficiency of machine as 50%, operating
factor as 60% and length of weld as 1 m.
(Nov/Dec 2012)
Estimate the machining time to drill four 8mm dia holes and one 40 mm dia central hole in he flange as
in fig. First 20 mm dia hole is drilled and enlarged to 40 mm dia hole.taking cutting speed 10m/min , feed
for 8mm drill 0.1mm/rev, for 20 mm drill feed is 0.2 mm/rev and for 140 mm dia the drill feed is
0.4mm/rev.

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(Nov/Dec 2018)

Consider the component as shown in figure.The component is to be made from mild steel with carbide
tooling at a constant surface speed of 100 m/min. on a lathe with a max spindle speed of 1500 rev/min

The machining allowance is 2 mm.Determine i) if the lathe is capable of turning the component ii) Total
machining time. (15)

(Nov/Dec 2018)

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