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B.E. / B.Tech (Full Time) D E G R E E END S E M E S T E R EXAMINATION, APRIL / MAY 2014

MANUFACTURING ENGINEERING

Fourth Semester

MF 8451 - P R O C E S S PLANNING AND C O S T ESTIMATION

(Regulation 2012)

(Tables Permitted)

Time: 3 Hours Answer ALL Questions Max. Marks: 100

PART - A (10 X 2 = 20 Marks)

1. What is a manufacturing system?

2. Define hybrid layout and its advantages
3. What is surface cutting speed?
4. What are the three basic principles of pin location?
5. What do you understand by reliable estimate?
6. Differentiate standard cost and estimating
7. (i). Drifting is an operation carried on by a special tool known as a drift to enlarge
the .
(ii). The portion of metal between the length held in the tongs and the material in the die
is called .
8. Why shrinkage allowance is kept in a pattern?
9. What machining time will be required to drill a 15 mm hole through a 50 mm thick sheet
plate? The feed for a 15 mm drill should be 0.2 mm per revolution and the rpm=1480.
10. Differentiate plain milling cutter and face milling cutter

PART- B (5 x 16 = 80 Marks)

11. (i).What is manufacturing strategy? Explain its six basic decision categories and functions
of manufacturing organization. (12)

(ii) Describe the process of document preparation in process planning (4)

12. (a) (i). Explain the various types of jigs used in drilling and boring operation with simple
sketch (12)
(ii) List some standard parts used in the design and construction of jigs and fixtures (4)

)
 (OR)
(b>. What is quality assurance? and how to control the quality in manufacturing industries.
Explain with closed loop control system (16)

13. (a).(i) Name the various elements which contribute towards total cost of the product.
Explain any two of them (6)
(ii) A concern manufacturing air coolers proposes to put up an improved model in the
market and you are required to suggest a selling price which will cover the on cost
and ensure the portion of profits on sales as before. The material in the new model
will cost Rs. 400 and direct wages would be Rs. 200. The following expenditures
relate to the previous year

Stock of material on 1 'April 1975

s
Rs. 20,000

Stock of material on 3 1 March 1976

st
Rs. 22,000

Purchase of raw material in this period Rs. 52,000

Manufacturing wages Rs. 16,000

Works on-cost Rs. 8,000

Administrative and sales on-cost Rs. 8,000

Sales during the year Rs. 90,200

(10)
(OR)

(b) (i). Find the material cost for the finished component shown in fig.1. The density of
brass is 8 gm/ cubic cm and cost of brass is Rs. 24 per kg. (8)
 (ii). Determine the depreciation fund which stands in the company's books, based on
reducing balance method, as on 1 st January 1983.

Cost of machine Rs. 14000

Cost of erection and installation Rs. 2000

Residual value of the machine after 10 Rs. 2000

years

Date of commission of the machine 1 st July 1980

Company's financial year From 1 st January to

31 st December

(8)
14. (a), (i) Define pattern and what are the important allowances should be considered for
making it. (6)

(ii). 150 pieces of shaft as shown in fig.2. are to be drop forged from the raw stock of
2 cm diameter. Estimate the cost incurred assuming that, material cost = Rs.5.20
per meter, cost of forging = Rs. 120.50 per sq. meter of surface area to be forged,
over head expenses to be 100% of the cost of forging.

3L di

*4*—70 —*|
(10)
(OR)
(b). (i) What are the factors that affect the welding cost. (4).

(ii) Two plates of each 100 cm. long, 25 cm wide and 5 mm thick are to be welded. A
60° vee is prepared by gas cutting prior to welding. The overall cost of oxygen is
70 paise per cu. metre, cost of acetylene Rs.7.0 per cu. metre and the cost of
filler rod material is Rs.3.0 per kg. Using leftward technique, find the cost of
cutting and welding. Take density of filler material as 11.28 gm/cu.cm. (12)
15. (a).(i) Write short notes on the following terms
1. Set-uptime
2. Operation time
3. Handling time
4. Tear-down time
5. Servicing time
6. Personal and rest allowances (6)

(ii) Estimate the time taken to prepare a job as shown in fig.4 from mild steel stock
bar 4.00 cm in diameter and 7.5 cm long. Assume the following data:
Cutting speed for turning and boring operation = 20 m/ min
Cutting speed for drilling operation = 30 m/min
Feed for turning and boring operation = 0.2 mm/ rev
Feed for 20 mm drill = 0.23 mm/rev
Depth of cut not to exceed 3 mm in any operation.

<P20 4>25 d>20

20 T ^ 2 5 »(• 30 -*|
(10)

(OR)
(b).(i) A 20 x 5 cm cast iron surface is to be faced on a milling machine with a cutter
having a diameter of 10 cm and 16 teeth. If the cutting speed and feed are 50
m/min and 5 cm/ min respectively, determine the milling time, RPM of the cutter
and feed per tooth.
(8)
(ii). What are the parameters need for calculating planer machining time and milling
time (8)