M11117,.1312M • .......■••••••■•-•.---.

BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI

ME F112: Workshop Practice
Comprehensive Examination: Closed Book
Max Marks: 80 Duration: 90 min. Date: 19th Feb, 2022
Note: Answer to-the-point. No credit will be given for writing multiple answers

An operator want to cut a blind groove in the center of a cubical workpiece on a vertical milling machine. Recommend
the sequence of operations and corresponding cutting tools to the operator to cut the groove. Justify y o u r
r e c o m m e n d a t i o n . [ 8 ]
j)(An operator want to machine a concentric through hole of diameter 62.32 mm in the center of a cubical workpiece on a
drilling machine. What sequence of operations you will recommend to the operator to machine hole with high
a c c u r a c y . J u s t i f y y o u r s e q u e n c e . [ 8 ]
Recommend the work holding device (s) for turning a hollow shaft of 500 mm external diameter, 490 mm internal
diameter and 1000 mm length. Justify your recommendation. [4]
Q2
A cubical casting of 50 x 25 x 10 mm3 is to be produced by the sand casting process. It undergoes 4%, 3% and 2% volume
shrinkage during the solid state, phase transition and liquid state respectively. Cubical casting has to be cast with a
cylindrical riser of height equal to diameter. Assume that the riser is not insulated to any surface. Volume of the riser
should be 4 times the shrinkage volume of the casting. Determine the minimum diameter of the riser
c o n s i d e r i n g a l l c o n s t r a i n t s . [ 1 5 ]
NX) A 200 mm long sprue has an area of cross-section of 650 mm2, where the pouring basin meets the sprue. A constant
head of molten metal is maintained by the pouring basin. The molten metal flow rate is 6.5 x 105 mm3/s. Considering
the end of sprue to be open to atmosphere and acceleration due to gravity of mm/s2, what should be the area of
the sprue in mm2 at its end to avoid aspiration effect? [5]
Q3
jf The thickness of a plate is reduced from 30 mm to 10 mm by successive cold rolling passes using identical rolls of
diameter 600 mm. Assume that there is no change in width. If the coefficient of friction between the rolls and the
workpiece is 0.1, then determine the minimum number of passes required to achieve the reduction. [5]
j6A 4 mm thick sheet is rolled with 300 mm diameter rolls to reduce thickness without any change in its width. The friction
coefficient at the work-roll interface is 0.1. Determine the minimum possible thickness of the sheet that can b e
p r o d u c e d i n a s i n g l e p a s s . [ 5 ]
AA Cast Iron block of side 40 mm is to be formed into a sheet of 12 mm thickness. Which cold forming process should be
used for manufacturing? Justify your selection. [5]
vc1) How can you differentiate between two rolled sheets made of same metal one by cold rolling and other by hot rolling
process? [5]
Q4
Identify the characteristics of a grinding wheel for rough grinding of a mild steel work piece? Justify your
s e l e c t i 8 o n [ ]
yiJustify whether a standard wooden pattern can be used for production of two identical (shape and size) casting of [4]
[4]
[4]
pure Aluminum and Copper.
* *** * *** *
v er Whether a strip requires pushing force to enter rolls? Justify.
Explain the influence of grain size on the permeability of moulding sand.
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