MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________

Important Instructions to examiners:

1) The answers should be examined by key words and not as word-to-word as given in the model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not applicable for
subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The figures
drawn by candidate and model answer may vary. The examiner may give credit for any equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values may vary and
there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer based on
candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent concept.

Q. Bit
Description/ Answer Marks
No No.

Q1 a. Attempt any Three of the Following 12

i) State the need and importance of non – traditional machining process.

( Two point each )
Need of non – traditional machining process.
Any 2
(1) The need to shape new metal alloys and non-metals that are difficult to machine by
2 marks
conventional processes;
(2) The requirement of unusual and complex workpart geometries.
(3) The need to avoid surface damage which is often associated with conventional machining
i) Importance of Nontraditional Machining process.

1. Material removal may occur with chip formation or even no chip formation may take
place.
Any 2
2. In NTM, there may not be a physical tool present.
2 marks
3. In NTM, the tool need not be harder than the work piece material.
4. Mostly NTM processes do not necessarily use mechanical energy to provide material
removal.
5. They use different energy domains to provide machining.

Fig 02
Marks

ii ii) Explain the working of wire-cut EDM process with neat sketch.

02
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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
Marks

The basic mechanism of metal removal in WEDM is identical to that in die sinking type EDM.
Instead of moving electrode, the electrode in this process is a moving wire of CU or brass. A
vertically oriented wire is fed into the work piece continuously travelling from a supply spool to
take a spool, so that it is continuously renewed , since it will get worn out during the process.

iii) State the meaning of G03 , G40, M03, M06

Codes in part programming Meaning

G03 Circular interpolation Anticlockwise

Each 1
iii
G40 Cutter diameter compensation Cancel Marks

M03 Spindle start Clockwise

M06 Tool Change

iv) Write down the classification of boring machine.

1.Horizontal Boring Machine
- Table type
- Floor Type
- Planer Type
iv 2. Vertical Boring Machine 4 Marks
- Stander vertical Boring Machine
-Vertical Turret lathe
3. Jig Boring Machine

4. Precision boring machine.

1 b. Attempt any ONE of the following 6

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
02 marks
i) Describe the working of LBM with neat sketch. State any two advantages of
LBM.

Laser(amplification of light by stimulated emission of radiation ) beam machining set up

consists of a stiumulating light source and a laser rod. The light radiated from the flash lamp is 02 marks
focused on to the laser rod from where it is reflected and accelerated in the path. This light is
emitted in the form of divergent beam. A lens is incorporated in the path of this beam of light
which converges and focuses the light beam on to the workpiece to be machined. This
concentration of laser beam on the work piece melts the work material & vapourises it.
Advantages
1. Good Surface finish with accurate profile can be obtained.
2. Extremely hard and brittle material can be easily machine.
3. Conducting as well as non - conducting material can be machined.
4. Any complicated shape can be produced.
02 marks

ii) State the importance of dry run in CNC machine, Enlist the safty procedures to
be followed while using CNC machine.

importance of dry run in CNC

02 marks
It is the trial run without actual running of CNC machine for checking correct shape of the
component. It shows correctness of the steps given in the program. It give idea about the tool
impact collision with the chuck and other machine parts due to incorrect program.
Safty procedures to be followed while using CNC machine.

1. Operators Should Have Proper Training

Computer Numerical Control (CNC) machining involves a technical process of controlling the
motion of parts and tools through a computer software that uses numeric data. Whether a CNC
shop has mills or lathes, the operators must be adequately trained to inspect, maintain, and use the
machine, brand, and controller type. Being skilled in the programming of CAD and CAM
programs is also essential for experienced users. 4 marks

2. The Area Around the Machine Must Be Free of Obstacles

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
Before a machining or tooling process is initiated, the machinist must inspect the machine to
remove any obstacles that may fly off and hit someone. The user must check the path of the router
to ensure that there are no screws that can stay embedded in the project. The floor should be clear
of sawdust and scraps to prevent any possible accidents.
3. Conducting a Dry Run Is Important

Before beginning the actual CNC machining process, the operator must conduct a trial run to
ensure that all moving parts are set and configured correctly. Most machines have a lock feature
that allows users to scan the program for mistakes. During this process, the spindle will run, the
control will execute the program, and the turret will index. However, only the axes (X, Y and Z)
will stay still.

4. Operators Must Dress Accordingly

Users should never wear gloves while operating the machine. Jewelry should be avoided as some
can conduct electrical charges as well as getting caught in machinery. Wearing loose clothing is
also prohibited since the operator risks getting pulled into the machinery, and this can be quite
fatal.

In any workplace, safety comes first. Operators must understand all the safety features on the
machine such as curtain guards, contact mats, guard fencing, soundproof casing, and emergency
stop button operation to ensure a safe CNC machining operation.
Q2 Attempt any FOUR of the following: 16

a) State any four essential requirements of dielectric fluid used in EDM

- Low viscosity

- High flash point

a) 04 marks
- Controlled level of toxicity

- Freedom from acid & alkaline products

- High electric strength

b) Explain Closed loop control system with neat sketch. 01 marks

b)

03 marks

The name indicates that the closed loop control system has a loop that is closed as shown in fig. A
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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
feedback device is used for this purpose. This makes the design of closed loop a little complicated
and expensive. But a very high degree of accuracy is achieved in the movement of slide.
This system is similar to open loop control system. But it consists of two additional devices in the
form of feedback transducer and a comparator as shown in Fig.
The transducer feedbacks the actual slide displacement to the comparator. The comparator
compares the actually achieved slide movement with command signal. If there is any error then it
is feedback to the MCU.

The MCU then sends the corrective commands to the drive unit and the cycle repeats until there is
no error signal from the comparator.

c) Explain the construction of planomiller with neat

02 marks

c)

1. Bed: A fixed bed is considered as the base of the machine.

2. Table : A table is mounted on the bed. The table has longitudinal movement only. 3. Column :
Two vertical columns, one on each side of the bed are mounted on the bed.

4. Cross rail: A cross rail is fitted on the column. It may be lowered or raised to suit the height of
the workpiece.

5. Milling Head: Two vertical milling head are fitted on the cross rail which can move towards
each other. Two horizontal milling head are mounted on the column which can move vertical over
it.

6. Milling cutter: Each milling head carries one cutter 02 marks

d) Write down the detailed classification of milling machine.

1. According to position / location of spindle
a. Horizontal milling machine
d) b. Vertical milling machine 04 marks
c. Special purpose milling machine.
2. According to design :
a. Column and knee type milling machine

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
I. Hand milling machine
II. Plain milling machine
III. Universal milling machine
IV. Vertical milling machine
b. Fixed bed type milling machine
I. Simplex milling machine
II. Duplex milling machine
III. Triplex milling machine
c. Planer milling machine
d. Special type of milling machine
I. Rotary table milling machine
II. Planetary milling machine
III. Profiling milling machine
IV. Duplicating milling machine
V. Pantograph milling machine
VI. Tracer contour miling machine
e) State the objectives and need of maintenance ( 2 point each)

objectives

- To minimize the number of breakdown.

- To keep plant in good working condition at the lowest possible cost. 02 marks
- To minimize the hindrance and interruption of work. Any 2
e) - To carry out the work of all the machines smoothly.
need of maintenance

• Maintenance should be planned at regular intervals to prevent uncalled breakdown.

• If proper attention is not given to the machine tool then it will fail. 02
• The maintenance of machine tool is needed to keep them in working condition at all the marks
times. Any 2
• The maintenance of machine tool is important to minimize the hindrance and interruption
of work.
f) Compare traditional and non-traditional machining processes. ( Four point each)

Traditional Machining Processes Non- Traditional Machining Processes

1. Generally macroscopic chip formation by 1. Material removal may occur with chip
shear deformation. formation or even no chip formation may
[any 4
take place. 2. There may not be a physical
f) points 4
2. There may be a physical tool present. tool present.
marks]
3. Cutting tool not harder than work piece
3. Cutting tool is harder than work piece 4. Mostly NTM processes do not
necessarily use mechanical energy to
4. Material removal takes place due to provide material removal. They use
application of cutting forces – energy different energy domains to provide
domain can be classified as mechanical machining. For example, in USM, AJM,

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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(ISO/IEC - 27001 - 2013 Certified)
SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
WJM mechanical energy is used to
5. Conventional machining involves the machine material, whereas in ECM
direct contact of tool and work –piece electrochemical dissolution constitutes
material removal.
6. Lower accuracy and surface finish. 5. Whereas unconventional machining does
not require the direct contact of tool and
7. Suitable for every type of material work piece.
economically 6. Higher accuracy and surface finish.
7. Not Suitable for every type of material
8. Tool life is less due to high surface economically
contact and wear. 8. Tool life is more
9. Higher waste of material due to high 9. Lower waste of material due to low or no
wear. wear.
10. Noisy operation mostly cause sound 10. Quieter operation mostly no sound
pollutions pollutions are produced.
11. Lower capital cost 11. Higher capital cost
12. Easy set-up of equipment. 12. Complex set-up equipment.
13. Skilled or un-skilled operator may 13. Skilled operator required.
required 14. Generally they are fully automated
14. Generally they are manual to operate. process.
15. They cannot be used to produce 15. Can be used to produce prototype parts
prototype parts very efficiently and very efficiently and economically.
economically.
3 Attempt any Two of the following: 16

Write a part program for a job shown in Fig No.1. Take only finish cut. Use, spindle speed =
a. 08
1500 rpm and feed rate = 0.1 mm/rev. Assume suitable data if necessary.

(02 Marks for Detailed Figure and Coordinates & 06 02

Point X- Z-
Coordinate Coordinate Marks for Correct Program)
Marks
Figure of work piece with its Coordinates
P0 0.0 5.0 for

P1 0.0 0.0 Detailed

P2 20.0 0.0 Figure,

An
s P3 40.0 -10.0 Coordin
ates
P4 40.0 -30.0

P5 60.0 -80.0
&
P6 60.0 -120.0

P7 70.0 -120.0

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
06

O1234; Program no. Marks

N001 G28 U0.0 W0.0; Return to reference position for

N002 G21 G90 G99 G97; Input in mm, Absolute Programming, Correct
Program
G99 for Feed in mm/rev&G97 for speed in
rpm

N003 M06 T0101 M08; Tool change tool no. tool offset no. coolant ON

N004 M03 S1500; Spindle Start clockwise with 1500 rpm

N005 G00 X0.0 Z5.0; Move the tool rapidly to point P0

N006 G01 X0.0 Z0.0 F0.1; Move the tool with Feed rate of 0.1mm/rev to
point P1 (Touch point)

N007 G01 X20.0 Z0.0; Facing Operation up to point P2

N008 G03 X40.0 Z-10.0 R10; After facing circular Interpolation CCW with
Radii =10 mm up to point P3

N009 G01 X40.0 Z - 30.0; After radius of 10 mm plain turning

up to point P4

N010 G01 X60.0 Z - 80.0; After that taper turning up to point P5

N011 G01 X60.0 Z – 120.0; After taper turning plain turning up to point P6

N012 G01 X70.0 Z – 120.0; Lastly tool is taken away from work piece

up to point P7

N013 M09 M05; Coolant STOP, Spindle STOP

N014 G28 U0.0 W0.0; Return to reference position

N015 M30; End of Program

b. Explain the working of PAM with neat labelled sketch. State its any two applications. 08

(03 Marks for Working, 03 Marks For Sketch & 01 Mark For Each Application )
An Plasma Arc Machining: 03
s Plasma-arc machining (PAM) is a metal removal process in which metal is removed by directing
Marks
high about 11000 to 30000 degree centigrade ionized gas on the work piece. The principle PAM is
shown in the figure. In this process, plasma torch is used in which a volume of a gas such as
Page 8 of 20
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
H2,N2,O2 is passed through a small chamber in which high frequency spark is maintained for
between cathode and anode. The plasma jet melts the work piece material. The depth of hat zone
depends on the work material ,its thickness and cutting speed. Working
,

03

Marks

For

Sketch

&

01

Mark

For

Each

Applicati
Applications of PAM:
on
(1) Cutting Alloy Steels, Stainless Steels, Aluminium and its alloys
(2) Used for turning and milling of difficult to machine materials
(3) Used for removing of gates and risers from a casting.
(4) Used in underwater operations like, in shipyards, chemical industries, nuclear power plat,
etc.
(5) Used for cutting of hot extrusions
What is the function of dividing head? Sketch and explain internal mechanism of universal
c 08
dividing head.

(02 Marks for Function & 04 Marks for Sketch & 02 Marks For Explanation)
Function of Dividing Head:
Function of dividing head is to divide the periphery of a workpiece into any number of equal parts.
For example:
An (1) If we want to make a hexagonal bolt. Head of the bolt is given hexagonal shape. We do
s indexing to divide circular workpiece into six equal parts and then all the six parts are milled to an
identical flat surface.
(2) If we want to cut „n‟ number of teeth in a gear blank. The circumference of gear blank is
divided into „n‟ number of equal parts and teeth are made by milling operation one by one.
Universal Dividing Head:

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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(ISO/IEC - 27001 - 2013 Certified)
SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
02

Marks

for

Function

&

04

Marks

for

Sketch

&

02

Marks
Figure: Internal Mechanism of Universal Dividing Head.
For
The worm gear has 40 teeth and the worm has simple thread. Crank is directly attached with the
worm. If we revolve crank by 40 revolutions the spindle attached with worm gear will revolve by Explanat
only one revolution and one complete turn of the crank will revolve the spindle only by 1/40th ion
revolution (turn). In order to turn the crank precisely a fraction of a revolution, an indexing plate is
used. An indexing plate is like a circular disc having concentric rings of different number of
equally spaced holes. Normally indexing plate is kept stationary by a lock pin. A spring loaded pin
is fixed to the crank which can be fixed into any hole of indexing plate. The turning movement of
the work piece is stably controlled by the movement of crank.

4 a Attempt any THREE of the following: 12

i Difference between up-milling and down milling (Four points each) 04

01

Mark
An
For
s
S. N. Up – Milling Down – Milling Each

Point

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
1

2 In Conventional Milling cutter In climb Milling cutter rotates in direction

rotates in direction opposite to that in same to that in which the work is fed.
which the work is fed.

3 The chip thickness progresses The chip thickness is maximum at the

gradually from start of cut to end of beginning of cut and minimum at the end of
cut cut

4 Cutting force tends to lift the Cutting force tends to seat the work piece
workpiece from the fixture. from the fixture.

5 Fixture design is complicated Fixture design is simple

6 Wavy surface finish is obtained Better surface finish is obtained

7 The cutter does not start cutting The cutter start cutting metal as soon as it
metal as soon as it come in contact come in contact with work piece
with work piece

8 The cutting force is downward at the The cutting force is upward at the beginning
beginning of cut and reaches to of cut and reaches to downward at the end of
upward at the end of cut. cut.

9 Chips get deposited on un- machined Chips get deposited on machined surface of
surface of work piece. work piece.

ii Explain gear hobbing process with neat sketch. 04

02

Marks

An For
(02 Marks For Sketch & 02 Marks For Explanation)
s Sketch

&

02

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SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
Marks

For

Explanat
ion

In this process of gear generating a tool is used known as hob. Hob teeth are shaped to match the
tooth space and are interrupted with grooves to provide cutting surfaces. It rotates about an axis
normal to that of the gear blank, cutting into the rotating blank to generate the teeth as shown in
figure.

It is the most accurate of the roughing processes since no repositioning of tool or blank is required
and each tooth is cut by multiple hob-teeth, averaging out any tool errors. Excellent surface finish
is achieved by this method and it is widely used for production of gears.

iii Explain honing process with neat sketch. 04

(02 Marks For Sketch & 02 Marks For Explanation)

Honing:-
It is a superfinishing operation used for previously machined surfaces.It is used for finishing 02
internal cylindrical surfaces, drilled or bored holes. The tool is called as Hone which is made out
of bonded abrasive stone made in the form of stick. The tool moves back & fourth while rotating Marks
about its axis.Honing operation can be done by two methods. For
a) Hand honing; for small lot of workpieces
b) Machine honing: for large scale Production Special Honing machines are used Sketch

&
An
s 02

Marks

For

Explanat
ion

iv What is repair complexity? State its use in maintenance of machine tools (Any two) 04

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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(ISO/IEC - 27001 - 2013 Certified)
SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
02
(02 Marks For Definition & 01 Mark For Its Each Use)
Repair Complexity: Marks

Repair Complexity is defined as the extent of complexity of machine tool considered for the For
maintenance work which is represented by a comparative index number. This number is called as
Definitio
repair complexity number .
n
Use of Repair Complexity in Maintenance of Machine Tool:
(1) If the repair complexity number is high, then repair cycle of the machine is longer because &
it consist high number of maintenance activities.
An (2) Repair complexity number is useful to decide the number of staff required for 01
s maintenance.
Mark
(3) To decide inventory of spares required for maintenance.
(4) To decide the repair cycle of the particular machine. For
(5) To find out the number of critical maintenance points of the machine.
(6) To forecast the maintenance cost of the machine or plant. Its
(7) Also repair complexity decides the time interval of repair cycle.
Each
(8) On the basis of repair complexity number maintenance schedule is prepared for the
machine or plant. Use
(9) For higher number long schedule is prepared while for small complexity number short
schedule is needed.

4 b Attempt any ONE of the following: 06

i Explain the stepwise process of manufacturing hexagonal shape on milling machine. 06

03
(03 Marks for Explanation & 03 Marks For Figure)
Straddle Milling Operation For Hexagonal Shape: Marks

[1] This is similar to the side milling operation. Two side milling cutters are mounted on the same for
arbour.
Explanat
[2] Distance between them is so adjusted with the help of spacing collars such that both sides of
ion
the work piece can be milled simultaneously.
[3] Hexagonal Shape can be produced by this operation by rotating the work-piece only two times &
An as this operation produces two parallel faces of hexagonal shape simultaneously.
s 03

Marks

For

Figure

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SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
ii Explain, how grinding wheels are specified 06

(02 Marks for Size Specification & 04 Marks For Remaining Specification)(Note: Figure is not 02
compulsory)
Grinding Wheel Specification: Marks
Example:
for

Size
Specifica
tion &

04

An 450 X 75X 101.6 ROS 200 X 2551 A 36 L 5 40 Marks

s D = 450 = Outer diameter of grinding wheel
T = 75 = width of grinding wheel For
H = 101.6 = Bore of grinding wheel
Remaini
ROS = Recess One Side
ng
P = 200 = Diameter of Recess
Specifica
F= 25 = Depth of Recess
tion
51 = Manufacturers Symbol.
A = Type Of Abrasive (Aluminium Oxide) (Note:
36 = Grain size (Medium) Figure is
L = grade (Medium) not
5 = structure (Dense) compulso
V = bond (Vitrified) ry)
40 = manufacture symbol (Optional)
5 Attempt Any Four of the following
a Explain repair cycle analysis. State its uses in maintenance of machine
Repair Cycle Analysis

The repetitive performance of maintenance activities between two overhauling (inspection) is

called as repair cycle analysis.

For maintenance planning repair cycle analysis is important. 2 Marks

foe
An Explanat
s ion and

2 Marks
for Use

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
Repair cycle analysis involves:

[1] Primary Inspection:-

Proper examination of the machine tool is carried to identify the problem. In this stage root cause
of the problem can be found out.

[2] Small Repair-01:-

In this stage as per the problem complexity cleaning or lubrication, type of small repair is
performed.

[3] Small Repair-02:

After repair one if the problem still exists another small repairs like alignment, proper assembly,
nut and bolt tightening is performed.

[4] Inspection:-

After small repair the machine tool is inspected for its performance.

[5]Major repair:-

If the small problem exists after small repair the major repair takes place like replacement of
component or machining is required.

[6] Inspection:

After major repair the inspection carried out for effective and efficient performance of that
machine tool.

Use of Repair Cycle Analysis

• It gives idea about staff required.

• Number of small/minor repairs.
• Number of major repairs.
• Number of spare parts (quantity required for maintenance)
b What is Burnishing State its advantages

Burnishing 2 Marks
Burnishing is super finishing process of obtaining a very fine surface finish having grainless for
appearance on metal objects. This process is used on various flat,cylindrical or conical surfaces. It Explanat
removes scratches and tool marks on the surface. ion and
An
s 1 Mark
each for
Advantages of Burnishing any 2
correct
1.There is no cutting action in this process. Only rubbing and peening action takes place. Advanta

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Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
2.It produces mirror like glazed and geometrically smooth surfaces. ges

3.Average 0.002 to 0.02 mm stock is removed from the surface.

4.Economical process as compare d to the other super finishing processes.

c What is meant by grinding wheel dressing? Why wheel dressing is necessary?

Dressing

Dressing removes loading and breaks away the glazed surface so that sharp abrasive
particles are again presented to work. A common type of star dresser is used to dress the wheel. 2 Marks
The dresser is held against the wheel and moved across the face of revolving wheel. Dressing is for
done to regain grinding wheels cutting capability. The dressing improves the surface finishing explanati
obtained while grinding. It is carried out where high degree of surface finishing is desired. on

An
s

and

Dressing of Grinding Wheel

Necessity of Grinding Wheel Dressing

[1] Dressing of grinding is done to improve the surface finishing obtained of the work piece
2 Marks
[2] Accuracy of the work piece. for
necessity
[3] It also increases the material removal rate

[4] Increase the life of grinding wheel

d Explain with neat sketch gear grinding using form wheel

An Gear Grinding 2 Marks

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SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
s Gear Grinding is a very accurate method and is, though relatively expensive, more widely used for for
finishing teeth of different type and size of gears of hard material or hardened surfaces. The Explanat
properly formed and dressed wheel finishes the gear teeth flanks by fine machining or abrading ion
action of the fine abrasives.

and

2 Marks
for
sketch

The grinding wheel is dressed to the form that is exactly required on the gear. Need of indexing
makes the process slow and less accurate. The wheel or dressing has to be changed with change in
module, pressure angle and even number of teeth. Form grinding may be used for finishing
straight or single helical spur gears, straight toothed bevel gears as well as worm and worm
wheels.

e Differentiate between capstan and turret lathe

Sr. No. Capstan Lathes Turret Lathes

1 The turret of capstan lathe is The turret of the turret lathe is directly
mounted on slides on the saddle mounted on bed
1 Mark
2 Less rigidity provided to the tool More rigidity provided to the tool each for
An
3 Suitable for light weight bar works Suitable for Larger and heavier loads any 4
s
correct
4 Handy for small components Larger works can be machined easily points

5 High production rate as fast cut is High production rate cannot be achieve
possible easily as larger and heavier parts do not
permit fast cut

f Sketch any two types of boring tools

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 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
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SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________

2 Marks
each for
An
any 2
s
correct
drawing

6 Attempt any Four of the following

A Define feed / tooth and feed / revolution in milling operations

a) Feed per tooth ( Sz):- The feed per tooth is defined by the distance the work advances in the 2 Marks
time between engagement by the two successive teeth. It is expressed in mm/tooth of the cutter. each for
An
each
s b) Feed per revolution (Srev):-The feed per cutter revolution is the distance the work advances definitio
in the time when the cutter turns through one complete revolution. ns

b Draw sketch showing different elements of broach and state the function of any two elements

2 Marks
for
Sketch

and
An
s
1 Mark
Elements of Broaches:-
each for
1) Pull end:- this is designed to permit engagement of the broach with the broaching machine any 2
2) Front pilot:- this centres the broach in the hole before teeth begins to cut correct
3) Roughing and semi finish teeth:- They remove most of the stock in the hole points
4) Finishing teeth:- they are for sizing the hole and must required shape of the finishing hole
5) Rear Pilot:- They support the broach after last teeth leaves the work piece
6) Land :- the top portion of the tooth is called as land
c Compare preventive maintennace with breakdown maintenance

An 1 Mark
SNo. Preventive Maintenance Breakdown Maintenance
s each for
Page 18 of 20
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
1 Actions performed on a time- or Breakdown maintenance is basically the any 4
machine-run-based schedule that “run it till it breaks” maintenance mode. No correct
detect, preclude, or mitigate actions or efforts are taken to maintain the points
degradation of a component. equipment
2 Reduced equipment or process Increased cost due to unplanned downtime
failure. of equipment
3 Less labor cost because of planned Increased labor cost, especially if overtime
maintenance. is needed.
4 Estimated 12% to 18% cost savings Cost is involved with repair or replacement
over breakdown maintenance of equipment
program.
5 Increased component life cycle. Possible secondary equipment or process
damage from equipment failure

6 Efficient use of staff resources Inefficient use of staff resources

d Enlist the advantages and limitations of broaching

Advantages 1 Mark
each for
[1] Advantages:- any 2
correct
1) Rate of production is very high advantag
2) Semiskilled operator can perform the operation es
3) High accuracy
4) High surface finishing
An 5) Both roughing and finishing cuts are perform in one pass
6) The process can be used for internal and external surfaces And
s

Disadvantages:- 1 Mark
1) High tool cost each for
2) Very large work pieces cannot be machined any 2
3) The surfaces to be broach cannot have an obstruction correct
4) Large amount of stock ( Material removal) cannot be removed disadvan
5) Work pieces must be rigidly supported tages

e What is cutter tool compensation? Why it is necessary in CNC machine part programming

When milling a contour, the tool radius center is used as the reference point on the tool while 2 Marks
writing the program, but the part is actually cut by the point on the cutter periphery. This point is for
An at 'r' distance from the tool center. This means that the programmer should shift the tool center Explanat
s away from the part in order to perform the cutting by the tool cutting edge. The shift amount ion
depends upon the part geometry and tool radius. This technique is known as tool radius
compensation or cutter radius compensation.

Page 19 of 20
 MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2013 Certified)
SUMMER– 18 EXAMINATION
Subject Name: Advanced Manufacturing Process Model Answer Subject Code: 17527
_________________________________________________________________________________________________
and

Necessity of Cutter Tool Compensation

[1] Cutter compensation allows programming the geometry and not the toolpath. 2 Marks
for
[2] It also allows adjusting the size of the part, based on the tool radius used to cut part. Necessity
[3] This is useful when cutter of the proper diameter is not found.

f State any four criteria of selecting the grinding wheel for any specific application

Selection criteria:-

1) Material to be ground:- Grain size , grade, structure, bond

2) Amount of stock to be removed:- This involves accuracy and surface finishing, coarse grain is 1 Mark
used for fast cutting & fine grains are used for fine finish each for
An
3) Area of contact:- Fine grain and closed grain spacing are useful where area of contact is small any 4
s
4) Type of grinding machine:- Heavy rigidly constructed machine used softer wheel. correct
5) Wheel speed points
6) Work speed
7) Condition of the machine
8) Personal factor

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