BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE,

HYDERABAD CAMPUS
PILANI
ID No:2021Au Ps2sgH
Name: Dev Singh Baghel Marks Scored:
Dt: 22nd August 23
TUTORIAL TEST -1 Max. Marks = 10 M
Q1,
In an orthogonal
36° Determine themachining operation, the uncut chip
natural contact length and change inthickness= 0.2 mm, rake angle= 10° and friction angle is
) only friction angle is it when
() only rake angle is increased by 10°
increased 10°
by

t sin Tly

ta 0.2 m m

cos 26°

() eee

change

chnge s 0.328- 0. 39S -5K7

 BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI
HYDERABAD CAMPUS
ID No: Marks Scored:
Name: Pev Singh Bag h 19
Dt: 6 Aug 2023 TUTORIAL TEST-2 Max. Marks = 10

21 for Discussion only (15 Minutes)

Q1.
Ahigh-speed steel tool is used to turn a steel workpart that is
300 mm long and 80 mm in diameter.
Tne parameters in the Taylor equation are: n= 0.13 and C=75
(m/min) for a feed of 0.4 mm/rev. The
operator and machine tool rate = $30.00/hr, and the tooling cost per cutting edge = $4.00. It takes 2.0
min to load
and unload the workpart and 3.50 min to change tools.
Determine (a) cutting speed for
maximum production rate, (b) tool life in min of cutting, and (c) cycle time
and cost per unit of
product.

Tutorial Question (35 Minutes)

Q2.

Acemented carbide tool is used to turn a part with a length of 14.0 in and diameter = 4.0 in. The
parameters in the Taylor equation are: n = 0.25 and C=1000
machine tool = $45.00/hr, and the tooling cost per cutting (ft/min). The rate for the operator and
unload the workpart and 1.50 min to change tools. The edge $2.50. It takes 2.5 min to load and
=
speed for minimum cost, (b) tool life in min of feed = 0.015 in/rev. Determine (a) cutting
cutting, and (c)
cycle time and cost per unit of product.
[3+3+4]

Ce2-s
0.2

) op
Topr 686.S8
 2

00 o
S-I2.44

Tope -

Cu

237t 2-57l.o7
-3-72
 BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI
HYDERABAD CAMPUS
ID Ne:olA4S49sH Name: AUiuk Khan Marks Scored:

Dt 13 Ang 2023 TUTORIAL TEST -3 Max Murt=10

Qlfor Discussion only (15 Minutes)

Q1

A 3.5 in dinmeter through hole is to be cut in a block of pure iron (Valence-2) by

electrochermical machining. The block is 2.0 in thick. To speed the cuting process, the
clectrode tool will have a center hole of 3.0 in which will produce a center core that can be
removed after the tooi breaks through. The outside diancter of the clectrode is ndersized to
allow for overcut, Tbe avercut is cxpected to be 0.005 inch on a side. If the efficiency of the
ECM operation is 90%, what current will be required to complete the cutting operation in 20
minutes? Consider, Specific removal rate for Iron is 0.000135 in A-min

Tutorial Question (35 Mimutes)

2.

The surface imegularties of electrodes used in an clectrochemical machining (ECM) process.

are 3 um and 6 um as shown in the figure. If the work-piece is of pure iron and 12V DC is
applicd between the electrodes, calculate the feed rate n mm'min. [10]
0.02 ohm mm
Conductivity of the clectolyte
Over-potential
Density of iron oltagc 1.5 V
7860 kg'm
55.85 gm
Atomic weight ofron
Assurme the iron to be dissolved as Fe and the Faraday constant to be 96500
Coulomb.

3ym

Work-piece(Iron)
 TUTORIAL TEST4
ME F315

Dey Singh Begal 20144Ps2y¢H Max. Marks = 10

20th Sep 2023
Q1 for Discussion only (15Minutes)
Q1.

Composition of a Nickelsuperalloy is as follows: Ni=70.0%,

Titanium. C=20.0%, Fe=5.0% and rest
Calculate rate of dissolution in ECM process if the
Aisbeing passed through the cell. area of the tool is
Assume dissolution to take place at1500 mm and a current of 2000
lowest valency of the elements.
A58.71 P8.9
A,=51.99 Z=2
Po=7.19
A=55.85 =7.86
-2
A=47.9 Pre
P4.51
Z =2

Where A-atomic weight in

gram, p -density in g/cm, Z=
valency
Tutorial Question (35 Minutes)
Q2 (a).
An alloy of density 6000 kg'ni IS]
consist of Iron and metal 'M.
Iron
Atomic weight=56 | AtomicMetal (M)
Valency2 weight-24
Valency=4
The volumetric material
removal rate of alloy is 50 mm/sec at a
Faradays constant 96500 coulombs/ mole. curent of 2000 A.
Calculate the percentage of the metal M* in the
alloy.
Q2 (b).
How far must the spindle travel
when cutting a 5.00 mm cavity in
steel by EDM process,
using copper electrode, and
(i) using copper tungsten electrode?
Assume wear ratio for copper electrode as 2:1 and for
copper tungsten electrode as 8:1.
2

MRP -3

FP Sox0
2000
 e=i4.45

+.
Ap

Deth of t S mm

Thuy
Thhe ore Bh
spindle mut truel st2.
() We

We

The

, 625 m
 BIRLA INSTITUTEOF TECHNOLOGY AND SCIENCE, PILANI
HYDERABAD CAMPUS

ID No: Marks Scored:

Name:
TUTORIAL TEST-5 Max. Marks = 20 M
Dt: 27h September 23

NOTE: Place is provided on the last page for marking options. It should be filled for evaluation. No "-ve
marking
1. Consider the following statements:
(i) Workpiece forms the positive electrode (anode).
(ii) Tool forms negative electrode (cathode).
(iii) Metal removal is governed by Faradayslawof electrolysis.
(iv)Tool wear is nmaximum.
which one of above statements, is correct for electrochemical machining?

(a) (i) and (ii) (i) and (ii) (c) (ii) and (iv) (d) (iv)

2 In electricdischarge machining, a better surface finish is obtained at

(a) low frequency and low discharge current
(b) low ffequency and high discharge current
ehigh frequency and low discharge current
(d) high frequency and high discharge current
produce holes with very small diameters?
3. Which of the following processes can be used to
(a) Electric discharge machining
(b) Elettrochemical machining
. KcYÉlectron beam machining
(d) Water jet machining current

wear in Electrical Discharge Machining (EDM) would be

4. Keeping all other parameters constant, the tool
less iffhe tool material has
KeYhigh thermal conductivity and high-specific heat
(b) high thermal conductivity and low specific heat
(c) low thermal conductivity and low specific heat
"(d) low thermal conductivity and high specific heat
to higher MRR in ECM?
5. Whichone of the following process conditions leads
(aHigher current, 1arge atomic weight
(b)Higher valency, lower current
(c) Lower atomic weight, lower valency
(d) Higher valency, lower atomic weight
maximum material removal rate
6 Arrange the processes in the increasing order of their
(a) USM, LBM, EBM, EDM, ECM
(b) EBM, LBM, USM, ECM, EDM
(C) LBM,EBM, USM, ECM, EDM
NaBM, EBM, USM, EDM, ECM
 I. In the ultrasonic machining process, the material renova] rate will be higher for materials with
(a) higher toughness (b) higher ductility owertoughness (d) higher fracture strain

8. MRR in ECM depends on

(a) Hardness of work material
bAtomic weight of work material
(c) Thermal conductivity of work material
(d) ductility of work material

9. Consider the following statements:

(). Irregularly shaped holes and cavities are easily produced
(ii), It has higher power consumption
(ii). Work and tool materials should be electrically conducting.
(iv). Metal removal is independent of discharge voltage.
Which of the above statement is true in case of Electrical discharge nachining (EDM)?

(a)(), (), (ii) and (ív)

aG) and (i) (b)(ii) (c)(i), (ii) and (iv)

(10. \Consider the following functions of dielectric fluids used in EDM:

1). It serves as a coolant
(i). It carries discharge
(m). It takes away the worn out work particles
(iv). It acts as an insulator in the gap between work pieces and tool.
of these
a) (i) arnd (i11) are true
(b) ( and (iv) are true
(O, (i) and (ii) are true
(d) ), (i), (ii) (iv) are true.
11. The metal remnoval in electro discharge machining depend on
(i). Discharge current (ii). Pulse frequency (iii). Pulse duration
Which of these?
(a) (i)is true (b) (ii) and (iii) are true (c) (i) is true and (ii) are true.

12. Consider the following machining methods:

i. Electron beam machining ii. Laser beam machining ii. Electric discharge machining
Which of the above methods uses thermal energ for removing work material?
g6). () and (ii) Ke), (ii) and (üi) (d). (i) and (ii)
(2). (i)

13. Consider the following work piece materials:

(i) Carbides (ii) Glass (ii) Copper (iv) Ceramics
Of these materials, which material is best suitsd for ultrasonic machining?
(a) (ii) (b) (ii) and (iii) Ne ), (ü) and (iv) (a) (ii), (ii) and (iv).
 20. 19. 18. 17. 16. 15. 14.
o "
IncreAsing
(c) volumethe "SM A Which (a) (iv) (ui) (i)Consider () andWhich
(a)() Consider () Which
(a) (iii)Consider (). (iii)Consider
() Which
(a) thConsider
eof()
Would 10 Specific Low Which
machining(ii) (i)Copper
(i) Processes Electron Electrochemical
(i) Electric Electron
ncreaseMRR má Equipment Close and i) and
and of of
metal methods and one
square the th e (i) the th e (ii) th e the (iv) the
not (iii) tolerances power is (ii)
above following
are abovefollowing dischargefollowingbeam (iv) not following
beam abovefollowing
change cost removal Tungsten
EDM(b) hole (b) can a
chipless
consumption machining bulk
statements
(ü), is are parameters produce machining materials is
MRR
concentration can not statements: machining methods:
difficult rate
(b)parameters: (b) (b)metal machining (b) materials:
be (i) very (iii)
() (ii) (), an () (ii)
cut and (ii) removal Molybdenum
" ishigh is and is ()
irregular and (iv) and used
(d) (b) LBM(c) in (iv ) true to true Poor Laser
a high. (ii) and (iv) methods: (ii)
Initially
Decrease of 2 achieve. (ii) machining
machining discharge
Electric
Laser
beam as
mm in surfacein Electrochemical
(ii) beam process?
abrasive ocase the hole? wire
thick case materials (iv)
decrease MRR ofnon-conventional finish machining
and Loi) (ii)
an d (i)(iandv) (c) (c)
Aluminum
in ECM(d) glass of
slurry (i) ultrasonic (iii) (ii), (i),
and plate machining (i) in
High (i) the
then would (a) and
by (), and wire-EDM
machining tooling (ii)
increase (i), (i v )
affect machining
(ii)
MRR s(d) cost (d) process
\o
MRR and (USM)? (d)
(), (), (), (ii),
in methods?
(iv)
the (i) (ii), (), (i)
folowing and (iii) (ii) and
(ii) and and (iv).
(iv) (iv)
manner
 BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI
HYDERABAD CAMPUS
DNo:
Marks Scored:
Name:
Dov Sinyh Baghel
Dt: 03rdOct 23
TUTORIAL TEST -6 Max. Mgrks =10 M

Tutorial Question (30 Minutes) [10 MJ

Q1for Discussion only (20 Minutes)
Q1.
During AJM, Mixing ratio used is 0.2. Calculate Mass ratio, if the ratio of
carrier gas is
equal to 20. density of abrasives and density of

Q2. Solve the following.

Estimate
Z gm/min,the MRR isin AJM of a brittle
velocity 200 m/s, material with
density of abrasive is 3flow strength
gm/sec.
of 4 GPa. The abrasive flow rate is

2x Lox&o,

Ma- L

4 9X

its actually correct

 HYDERABAD CAMPUS ENCE, PILANI
1p Ne: 202|A4p 33H Name:Anletrolig
D:0S"November 23 TUTORIAL TEST -8 Marks Seored: S
Max. Marks = 10 M

1.
Consider the parts in Fig. 1. Define the relevant geometries (Only Point).

(6)
LN1
P1

70
P2
LN2
-75
(a)
Y (5)
CR1 LN3 P48

P3A CR3

P38 P4A CR2

(O (c)
X
X
(d)
h=poNTAeMAL) NTO, LNB, Ce1
P34-fOINTI XLALGE, IWTO6 LN3,(RL Figure 1
Ps poNT (XLAR nE, | KTOF,CP 2,Ce3
 , Consider the parts in Fig. . Define the relevant geometries (Only Circle).

C1 c2
PT1
R372

62
LN1
X
(a) (b)
Y
4-LN2
PT2
LN3
(CAB) (CAA) R1S
(cAcCá
PT4

(c) ()

Figure 2

c)C= CIRCLEI CENTERI6l-0, 62.0,AD (usg4 o

L) CL= CecLE ICTEe, T1, TANTOA
b)
(c) c3s CIec LEI PT2, T3, PTY
clRcLE /YLARGE,AN2, 4LAR GELN3, RADV&,1S.0
(d) yLARInAoNS, )5:0

Aoe CiRcEIYSHALI LN3, XLARhE,LN,LAoVis.0

 BIRLA INSTITUTE OF ECHNOLOGY AND SCIENCE. PILANI
HYDERABAD CAMPUS

Ps log R Name: utse Patait plarks Seored:

ID No: o2 t A5

TUTORIAL TEST - 9 Mal Marks 10

Dt: 15 Nov 2023
Qlfor Discussion only (15 Minutes)

Q1.
with amplitude a).
Calculate the ratio of R./R, a square wave (square wave

Square wave

Time +

Tutorial Ouestion (35 Minutes)

Q2.

a sine wave
Calculate the ratio ofRa/Rg for
wave with amplitude
The equation of a sine
a is
y= sln1

Sine Wave
 7

[o-]