Question Paper Code : 90873 B.E/B.Tech. DEGREE EXAMINATIONS, NOVEMBER/DECEMBER 2022. Seventh/Eighth/Nineth Semester Mechanical Engineering ME 8793 - PROCESS PLANNING AND COST ESTIMATION (Common to Manufacturing Engineeri ial Science and . ° ' Engineering/ /Material : Engineering/Mechanical Engineering (Gandwichy/Mechanical and Automation Engineering/Mechatronies Engineering/ /Production Engineering/Roboties and Automation) (Regulations 2017) Maximum : 100 marks Time : Three hours PP w ys ex 10. 11. @ Answer ALL questions. PART A — (10 x 2= 20 marks) List the variables to be considered while purchasing a machine to a manufacturing unit. What is the current importance of Computer Added Process Planning (CAPP)? What is the purpose of Process Planning? What costs are associated with manufacturing? Draw the cost ladder diagram with its constituent cost elements. Draw the block diagram to show the build-up of total cost and selling price of a component. What factors are considered while evaluating the cost of a welded joint? What is shrinkage allowance? What are the elements of machining time? What are the standard data requirements for calculating cutting time in a shaping operation? PART B— (5 x 13 = 65 marks) Using proper sub-headings, explain the steps in the process selection process with an example. Or (6) Draw a component of your choice and discuss the steps to be performed in production equipment and tool selection process.13. 14. b) (a) ) (a) A compon, ent can be prod lathe. The different con faeteng neither & tore forthe ens caratan lathe of an automatic ‘ines are given below. Fixed cost = Re.500 Variable cos t= Re 3 Machine 11 3 per piece Fixed cost = Rs.1,500 Variable cost = Ra.1 per piece Assume that cyc yele ti the machines, Which fF Productio ich machine will you of the component is same for bot ‘You select for produci a ing ( 800, (ii) 700 components? Mm Or 6 Discuss the ste PS involved in engineer conclude your view on the mat Eigasing stiviies and s0 90 need of Operation planning sheet. Explain th xp e methods of costing followed in a manufacturing unit. Or Detail the elements of cost u dings. inder suitabl ‘A llap welded joint is to be made as shown ri teow ms es Weld : + 10mm 10mm x, Figure. 1 Lap welded joint Estimate the cost of weld from the following data: @ Thickness of plate = 10mm (i) Electrode diameter = 6mm (ii) Minimum are voltage = 30 Volts (iv) Current used = 250 Amperes (v) Welding speed = 10 meters/hour (vi) Electrode used per meter of weld = 0.350 kes (vii) Labour rate = Rs, 40 per hour Rs. 3 per kWh (viii) Power rate (ix) Electrode rate = Rs, 8.00 per ke (%) Efficiency of welding m/c = 50 percent 04 (xi) Connecting ratio (xii) Overhead charges (xiii) Labour accomplishment factor Or 80 percent of direct charges = 60 percent 90873) A P the ete Component is to be manufactured as per figure 2. Estimate ' Price per piece from the following data: ay of material = 7.2grams/ec ce of molten metal at cupola spout = Re, 20 per ke, ess scrap 20% of net weight Scrap return value = Rs. 6perkg = Rs.30 per hour Administrative overheads = 20 percent of factory cost Sales overheads Profit = 20 percent of factory cost Other expenditures are: Operation Time Labour cost/hour Shop overhead/ (minutes) in rupees. _—_—=hour in rupees Molding and pouring 15 20 60 Shot blasting 5 10 ay Fettling 10 ” EN WY i % et (a) Component as cast (b) Finished component Figure 2 All dimensions are in mm 15. (a) ATT-slot is to be cut in a C.I slab as shown in figure 3. Take cutting speed 25 m/min feed is .25 mm/rev. Diameter of cutter for channel milling is 80 mm. Estimate the machining time. Figure 3 All dimensions are in mm Or 3ining time to turn the dimensions shown in figure 4 ne] bar of 100 mm, The cutting speed with HSS @) Calculate the mach 2.0.8 mm/rev., depth of cut is 3 mm per pass starting from @ mr tool 80 m/min and d feed Figure 4 ‘All dimensions are in mm PART C — (1x 15 = 15 marks) der the component as shown in figure 5. The component is to be made from mild steel with carbide tooling at a constant surface speed of 100 m/min. on a lathe with a maximum spindle speed of 1500 rev/min. The machining allowance is 2 mm. 16. (a) Consi Determine : @ if the lathe is capable of turning the component at the required ® surface speed; le. (i) _ the total machining time for the component if the lathe is capabl @ Figure 5 Cylindrical Component All dimensions are in mm Or Iculation by considering basic (b) Discuss the importance of machine time cal rat least 2 different formulae, tables of variables and constants for machining operations with appropriate examples. 4 90873