Product Design & Manufacturing (PDM) : Subject Code 13ME413

Question Bank:
I. 2 marks Questions:

1. Define Product Design

2. Define Allowance (A) & Tolerance (T) with an example

3. Define Process Capability (P)

4. Define Product Development

5. Give 2 examples for Design by Evolution

6. Give 2 examples for Design by Innovation

7. Name 4 processes of Production-Consumption cycle.

8. Name 2 apparently independent variables - a combination by which "A Fit can be

obtained".

9. Define Preferred Numbers (Renard Series).

10. Name 2 types of Mechanical failures.

11. The C-clamp can fail by _________________ _________________ in Zone A,

_______________ ______________ in Zone B, _________ __________ of screw
threads in Zone C, and ________________ _____________ in Zone D. (Fill in the
blanks with suitable technical words).

12. The conversion of resources into raw materials is normally done by 2 subdisciplines
of Engineering : __________________ and ________________ (Fill in the blanks with
suitable technical words).

13. A material is often subjected to _______________ ______________ for producing

standard shapes such as those of rods, bars & sheets.

14. ______________ _____________ is performed when the objective is to obtain a

shape other than the standard shapes.

15. Unlike the fundamental subjects in science & engineering, the subject dealing with
the production processes is ___________________ in nature.

16. Define Machining Process.

17. Name the 2 basic principle of generation during Machining process.

18. Name the 4 common methods of Machining process.

19. Name any 4 common methods of Non-traditional machining processes.

20. Briefly explain Laser Beam Machining (LBM).

II. 3 marks Questions:

1. Name 3 different types of Fits.

2. Name 3 disadvantages of Design by Evolution.

3. Name 4 activities to be considered by the Designer while Planning for an effective &
flexible system of distribution of the designed goods.

4. Draw a neat sketch to illustrate the concept of Allowance in a Shaft-Hole combination

& briefly explain the different types of Fits.

5. Draw a neat sketch to illustrate the relationship between Tolerance (T) & Process
Capability (P).

6. Name the 3 Criteria & Objectives of Design

7. Name the 3 major processes, a component undergoes before it is converted into a

final product.

8. Name the 3 Engineering activities that require an understanding of the production

processes.

9. Name the 3 Focus areas for a successful casting operation.

10. Briefly explain the terms : a) Pattern, b) Flask & c) Core

11. Briefly explain the non-traditional machining process - Ultrasonic Machining (USM)
with the help of a neat sketch.

12. Briefly explain the non-traditional machining process - Abrasive Jet Machining
(AJM) with the help of a neat sketch.

III. 5 marks Questions:

1. Describe in brief with the help of a figure "Design Tree for protection device in
Automobile head on Crash" to illustrate Determination of Physical Realizability through
use of Design Tree.
2. Describe in brief with the help of a figure / flow diagram for the "morphology of design
process".

3. Name / write the 7 phases for the "Morphology of Design".

4. Name / write the 8 factors which are to be considered while designing for
Consumption.

5. Draw a neat sketch to illustrate the Fundamentals of a Limit System (both Designer's
concept & Manufacturing Specification.

6. Name the 4 product Strategies which affect the design of the product & explain in
brief each one of these.

7. Name the factors which have to be considered for analysis in relation to development
& design factors of the product.

8. Define Standardization, Simplification & Specialization - 3 related subjects which are

at the root of any economic analysis of product design.

9. Name / write the 5 activities which covers Standardization.

10. Name / Write the 7 advantages of Standardization.

11. Name the 5 basic Design considerations.

12. Write the 3 basic types of problems faced by Industrial Designer

13. Write the 4 types of Models Designed by Industrial Designers.

14. Write 5 strategies to be considered for Functional Design while Designing

Engineering products.

15. According to the Design Philosopher Morris Asimow, name the 5 aspects to be
considered while Designing for Product retirement.

16. According to the Design Philosopher Morris Asimow, name the 6 steps of Feasibility
Study (Phase I)

17. Define principal stress trajectories & explain with the help of 2 diagrams.

18. What is stress concentration & how force line travels in the following elements

a) Rectangular plate with a circular hole, b) Rectangular plate with a notch at 2 opposite
sides of the plate, c) A circular rod with a reduced Cross section.

19. Briefly explain Balanced Design with an example.

20. Briefly explain the precautions to be taken while designing the structure with
curvature.

21. Briefly explain the concept of Balanced Design for a Gear train with the help of a
neat sketch

22. Briefly explain 3 common types of design strategies outlined by "Chow".

23. Briefly explain care to be taken while designing an element "uniform strength"

24. Briefly explain the concept of Tension vs Compression from the view point of
Balanced Design.

25. Briefly explain the methods of reducing stress concentrations.

26. Briefly explain the Non-traditional machining processes - Electrochemical Machining

(ECM), Electric Discharge Machining (EDM) & Electron Beam Machining (EBM).

IV. 10 marks Questions:

1. Write / List the Essential factors of Product Design (14 factors)

2. Name the 10 steps of Preliminary Design (Phase II)

3. Name the 9 steps of Detailed Design (Phase III)

4. Write & Explain with help of a neat sketch, the various relationships in design,
production & marketing.

5. Briefly explain the 5 strategies used by the Product Designer for Engineering
Products during functional design practices.

6. Briefly explain the 4 types of models designed by Industrial Designers.

7. A quenched & toughened glass plate can support 4 times the bending load than that
of the regular glass plate - briefly explain with a neat sketch the Heat treatment cycle &
development of initial stresses in toughened glass.

8. Name the 12 types of Moulds & / Moulding.

9. Briefly explain the 6 steps involved in the precision moulding process.

10. Briefly explain the 4 important criteria as Design considerations for Casting - A
Product Designer need to consider who selects casting as the primary manufacturing
process.

*****