302066: Process Planning & Tool Selection (Self-study)

UNITWISE QUESTION BANK

Unit 3 Work-piece control and selection of operations

Work piece control: Causes of work-piece variations, influencing work-piece control variables,
techniques of work piece control – Equilibrium theories, concept of location, geometric,
dimensional and mechanical control.
Classification of operations: Basic Process Operations, Principal and Auxiliary Processes,
identification of major, critical, qualifying, re-qualifying and supporting operations, product and
process critical area.
1) What are the reasons of work-piece variations? Explain.
2) Explain with neat sketches geometric control for:-
i) Long cylinders ii) Short cylinders.
3) How locators are arranged in 3-2-1 pattern? Explain with suitable example.
4) What are the rules for locating long cylinder and short cylinder? Explain
with neat diagram.
5) What do you mean by major operations, critical operations, qualifying
and re-qualifying operations and how to identify them?
6) Discuss the concept of standardization and interchangeability.
7) What is an auxiliary operation? How can supporting operation be distinguished from
auxiliary operation?
8) What is mechanical control? Explain with suitable example.
9) What do you mean by major operations, critical operations? How to identify critical
operations.
10) How can supporting operation be distinguished from auxiliary operation?
11) What are the rules for combating tool forces and holding forces?
12) What are the advantages and disadvantages of combining operations?
13) For a cube of 20 cm size, sketch six locators needed for equilibrium, and Explain why the
locators are generally arranged in 3-2-1 pattern.
14) What do you mean by qualifying and re-qualifying operations and how to identify them?
15) How to identify critical operations from part drawing?
16) Explain mechanical control in relation to work-piece control.
17) Define work-piece control, What are the variables which interfere with work-piece
control?- Discuss.
18) Explain geometric control for cylindrical shapes.
19) What is mean by V-location? What error is caused by improper location of a V-locator?
20) Explain dimensional control and mechanical control in relation to work-piece control.
21) Discuss the various systems for controlling the position of a centerline with sketch.
Unit 4 Equipment & Tooling Selection
Types of tooling: Cutting tools, forming tools, Assembly tools, Factors affecting selection of
tooling, Cutting tool materials, Desirable properties of tool material,
Jigs and Fixtures: Design principles of jigs and fixtures, Types of locators, various of clamping
devices , Types of bushes, Economics of Jigs and fixtures, Indexing devices

1) Explain the prime accuracies & producible accuracies of equipment.

2) Distinguish between General purpose machine (GPM) and special purpose Machine
(SPM).
3) Explain the design principles for Jigs and Fixtures.
4) What is meant by tooling economics, How it is applied in process engineering?
5) What do you know about 3-2-1 principle? Explain with figure.
6) Define a Jig and Fixture. State any four functions of jigs and fixtures.
7) Explain the steps involved in machine selection method with a neat flow chart.
8) What are the most influencing factors in terms of tool performance?
How selection of cutting fluid will affect on tool performance in
various processes?
9) What are various factors affecting the machine selection? Explain.
10) What sources of information usually available to the process engineer to assist him
making a machine selection?
11) What are the main constraining factors on tool selection?
12) Compare jigs and fixtures. State its importance.
13) Which are the various cutting tool materials employed during manufacturing? How do
you select tool material?
14) What is mean by locating and clamping the work-piece? What are the various locating
devices?
15) What are the constraints in tool selection? Which are the most influencing factors in order
to determine the tool performance.
16) Explain briefly the relation between process selection and machine
Selection.
17) What are the types of drill bushes? Explain any two with neat sketch.
18) What are the principles of location?
19) What is a tool inserts and how it is used? What are the benefits of using Inserts over
solid tools?
20) What do you mean by ‘Commercial tooling, , ‘Regular tooling’ and
Special tooling?
21) What are the main type of tooling generally employed in casting, shaping and forming?
22) What other type of tooling can be used with drilling, besides drilling tools? Explain with
sketch.
Unit 5 Economics of Process Planning
Definition, Cost accounting, Elements of cost, Estimation of cost elements, Methods of cost
estimation, Data requirement for cost estimation, Steps in making cost estimation, Factors in cost
estimation, Selection of process parameters, Machining time calculations, Estimation of total unit
time.

1) What costs contribute to the production cost?

2) What are the process parameters for turning operation? How do you select Process
parameters?
3) What do manufacturing organizations use financial information for?
4) Describe the main costs associated with manufacturing.
5) What costs are associated with manufacturing?
6) What are the process variables considered in calculation of machining time? How do you
calculate machining time for drilling operation?
7) What is job and batch costing?
8) What other costs are used with the production costs to estimate the total
cost?
9) How does surface finish and material relates to manufacturing cost?
10) How do you calculate machining time for Turning and drilling operations?
Explain with suitable sketch.
11) What is variable and fixed costs involved in producing a product?
12) Write a note on ‘Economics of Process Planning’
13) What is a 'make or buy?' decision? Explain with flow chart.
14) What are the three classifications of part that are used in a make or buy scenario?
15) Write a note on ‘Break-even analysis’
16) What are the factors involved in calculation of machining time. How to Calculate cycle
time?

Unit 6 Process Sheet Design

Steps in process planning, Process symbols, routing description, operation number and
description, Preparation of process picture sheet, Operation route sheet for complete
manufacturing part, Calculation of cycle time.
Computer aided process planning: Advantages over manual process planning, approaches for
CAPP: Generative Process Planning, Knowledge-based Process Planning, Feature Recognition in
Computer Aided Process Planning, recent trends.

1) What information does the process picture provide? List some of the possible uses of
process picture.
2) Discuss various steps involved in manual process planning.
3) Draw a format for operation route sheet and explain its elements in short.
4) Explain the benefits of computer aided process planning (CAPP).
5) Which process symbols used while making process pictures?
6) Explain the steps involved in process planning.
7) Discuss the role of CAPP in modern manufacturing.
8) What information is provided on process picture sheet?
9) Explain the benefits of computer aided process planning (CAPP).
10) What information is provided on operation route sheet?
11) Explain the Automatic Time Standard System (ATS) in CAPP.
12) What is an operation routing? Which departments in the plants make use of routing?
13) What information is provided on process picture sheet?
14) Explain Retrieval Computer Aided Process Planning approach and
15) Draw general procedure chart of retrieval CAPP.
16) Explain the need of CAPP. Also discuss the role of expert system in Generative
Computer Aided Process Planning (CAPP) system.