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Analyze the effect of process variables on surface roughness in EDM process. Explain the applications and limitations of EDM process. A circular hole of 10mm in low carbon steel of 8mm thickness has to be performed in EDM process. The resistance and capacitance in the R-C circuit are 50 and 10F respectively. The supply voltage is 200 volt and the gap is maintained at such a value that the discharge takes place at 150 volt. Estimate the time required to complete the hole. Material removal rate in AJM is 0.5 mm3/min. Calculate material removal per impact if mass flow rate of abrasive is 3 gm/min, density is 3 gm/cc and grit size is 60 m as well as indentation radius. The composition (% by weight) of Nimonic 75 alloy is given here: Ni (72.5), Cr (19.5), Fe (5.0), Ti(0.4), Si(1.0), Mn(1.0)and Cu(0.6). Calculate material removal rate in cm3/min in ECM process when a current of 1000amp is passed. Ni = 8.9 Ni = 2 ANi = 58.71 ACr = 51.99 Cr = 7.19 Cr = 2 AFe = 55.85 Fe = 7.86 Fe = 2 ATi = 47.9 Ti = 4.51 Ti = 3 ASi = 28.09 Si= 2.33 Si = 4 AMn = 54.94 Mn = 7.43 Mn = 2 ACu = 63.57 Cu = 8.96 Cu = 1 Define Automation? Briefly explain different types of automation with suitable examples? Explain the different reasons for Automation? How does Computer Assisted Part programming differ from Manual Part Programming?

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In what way is the structure of NC machine tools differs from conventional machine tools? Define NC? What are its basic components? Discuss different types of NC systems? What is DNC? Illustrate the general configuration of DNC system? What are the different interpolations used in NC programming? What is the purpose of Part Program? Describe the various coordinate systems and choices of Zero position in NC system. 15. Define MLT and explain different parameters associated in it? 16. The outline of the part is to be profile milled, using a 18mm diameter end mill with three teeth. The part is 15 mm thick. Cutting speed = 100 mm/min and feed = 0.10 mm/tooth. Use the lower left hand corner of the part as the origin. Write the APT statement for producing the part.

17. The outline of the part is to be profile milled, using a 12.5 mm diameter end mill with two teeth. The part is 7.5 mm thick. Spindle speed = 500 rev/min and feed rate = 0.80 mm/min. Use the lower left hand corner of the part as the origin. Write the APT statement for producing the part. 18. What is High energy Rate Forming Processes? Briefly explain the Explosive Forming process. Discuss different types of explosives used. 19. Obtain the expression for MLT in Job shop production and Mass production? Obtain the mathematical model of Production Rate and Plant capacity. Three products are to be processed through a certain type of work centre. Pertinent data are given in the table. Determine the number of work centers required to satisfy this demand, given that the plant works 10 shifts per week and 6.5 hr available for production on each work centre for each shift. The value of nm=1. 20. Write notes on a) Functions of manufacturing b) Plant lay out

Product 1 2 3

Weekly Demand 600 1000 2200

Production Rate(Unit/Hr) 10 20 40