List of top Manufacturing Processes Questions

In the composite filament winding process as shown in the figure, the mandrel diameter is 700 mm and is rotating at a speed, \( N = 6 \) rev/min.
If a \( 45^\circ \) helical winding angle is needed, the axial velocity, \( v_c \), of the slider should be ______ m/s (rounded off to two decimal places).
Assume \( \pi = 22/7 \). Ignore the thickness of the composite layers already wound on the mandrel.

Note: Figure is not to scale.

Which ONE or MORE among the following work materials is/are NOT commonly machined using diamond cutting tools?

Iron powder produced by gas atomization has a tap density and an apparent density of 3.26 g/cm\(^3\) and 2.66 g/cm\(^3\), respectively. The density of solid iron is 7.85 g/cm\(^3\).
Which ONE of the following options is the closest approximation to the degree of densification (in percentage) of this iron powder?

A sheet metal drawing is considered feasible if the following conditions are met:

Reduction ratio < 0.5
Thickness to diameter ratio > 1%

A sheet metal drawing process is being planned on a sheet metal with a thickness of 2 mm with a punch of diameter 100 mm with various blanks of diameter \( D_b \).
Which ONE of the following blank diameters \( D_b \) (in mm) will result in feasible drawing?

Which ONE of the following options CORRECTLY matches the machining process and associated predominant material removal mechanism?

Advanced machining process		Predominant material removal mechanism
P	Laser beam machining	1	Impact based erosion
Q	Abrasive waterjet machining	2	Sputtering
R	Ion beam machining	3	Melting and vaporization
S	Mechanical milling	4	Shearing

A modified Taylor tool life equation is given as follows:
\[ V T^n f^m = constant \]
where \( V \) is the cutting speed (m/s), \( T \) is the tool life in minutes and \( f \) is the feed in mm/rev, \( n = 0.25 \) and \( m = 0.5 \). Under two different cutting conditions \( (V_1, f_1) \) and \( (V_2, f_2) \) the tool life \( (T_1, T_2) \) was found to be the same.

If the ratio of the cutting speeds \( (V_1/V_2) \) used is 2/3, then the ratio of corresponding feeds \( (f_1/f_2) \) must be ______ (rounded off to two decimal places).

In a polymer extrusion process, some cross-sectional shapes of the extruded polymers are shown. Cross-sections of available dies are also shown.
Which ONE of the following options CORRECTLY matches the extruded cross section with the die opening that most likely generated it?
Note: The cross-sections are in a plane orthogonal to the extrusion direction. Figures are not to scale.

Which one of the following fusion welding techniques results in least Heat-Affected Zone (HAZ)?

The welding process commonly used for fabricating tailor-welded blanks of dissimilar thickness for automotive applications is

Two metal parts (a cylinder and a cube) of same volume are cast under identical conditions. The diameter of the cylinder is equal to its height. The ratio of the solidification time of the cube to that of the cylinder is _______________ (rounded off to 2 decimal places).
Assume that solidification time follows Chvorinov's rule with an exponent of 2.

A plate of 30 mm thickness is fed through a rolling mill with two powered rolls. Each roll has a diameter of 500 mm. The plate thickness is to be reduced to 27 mm in a single pass. Assume no change in width. The process feasibility and the maximum draft (in mm) can be represented, respectively, as
Use the coefficient of friction as 0.12

Consider two infinitely long fins made of the same material and exposed to the same convective environment. One fin has a square cross-section of side \(a\), and the other has a circular cross-section of diameter \(d\). Assume \(a = d\). The ratio of the steady-state heat transfer rate from the square fin to that from the circular fin, \(\frac{\dot{Q}_{\text{square}}}{\dot{Q}_{\text{circular}}}\), is:

A cantilever beam of length \(L\) is fixed at the left end (\(x=0\)). It is subjected to a concentrated downward point load \(P\) and a concentrated clockwise moment \(M = \frac{PL}{2}\) at the midpoint (\(x = L/2\)). Which of the following descriptions correctly represents the Shear Force Diagram (SFD) for the beam?

A vibrating system has a critical damping coefficient \(C_c = 350 \, \text{N}\cdot\text{s/m}\) and an actual damping coefficient \(C = 35 \, \text{N}\cdot\text{s/m}\). The logarithmic decrement of the system is approximately: