Saturday, November 26, 2016

ME6005 Process Planning and Cost Estimation Nov Dec 2016 Important Questions

Important questions / expected questions for Nov Dec 2016 ME6005 Process Planning and Cost Estimation examinations conducting by Anna University Chennai
07th Semester / Seventh Semester / IV Year
Department of Mechanical Engineering
ME6005 Process Planning and Cost Estimation
(Regulation 2013)
Nov Dec 2016 Important Questions

Important 16 Marks Questions with answers (All five units) are listed for ME6005 Process Planning and Cost Estimation subject

1. (a) Identify the steps involved in Process Design. (8)
(b) Examine the basic factors affecting Process Design. (8)

2. Show the two approaches to Process Planning in the context of CAPP (Computer Aided Process Planning)? Explain them clearly. (16)

3. (a) Describe the steps or procedures involved in Process Planning. (10)
(b) Show the data is listed for each component of the product in the process sheet.(6)

4. (a) Classify the four distinct processing strategies (8)
(b) Summarize the process layout with neat sketch. (8)

5. Illustrate the three analyses that can be carried out during drawing interpretation. (16)

6. Summarize the general recommendations for cutting depths for turning, boring, milling and Drilling? (16)

7. For the part shown in Fig. calculate the maximum surface speeds for facing, turning all surfaces and parting off. The maximum spindle speed of the lathe being used is 600 rpm. (16)
8. Describe depth of cut and what are the most important factors that affect the depth of cut possible when machining? (16)

9. A large computer manufacturer requires 1200 printed circuit board (PCB) carriers every month for the production of the PCBs themselves. Within their tool room, they have a variety of machining processes available and the carriers are produced on a conventional milling machine. The following information relates to the PCB carrier manufacture: (16)
Set-up time 1 h 20 min
Machining time 39 min
Material cost/unit Rs.5.62
Machinist’s hourly rate Rs.9.85/h

10. Consider the component shown in Fig, and design a suitable type of jig for drilling the Ø10 mm holes, assuming the holes are manufactured last. (16)
11. (a) Discuss the objectives of cost estimation (10)
(b) Give the advantages of cost accounting (6)

12. Describe step by step procedure for estimating the direct material cost (16)

13. (b) Give the basic steps in cost estimation (8) BT2
8 Calculate prime cost, factory cost, production cost, total cost and selling price per item from the data given below for the year 2012-13 (16)
Cost of raw material in stock as on 1.4.2012 - Rs 25,000
Raw material purchased - Rs 40,000
Direct labour cost - Rs 14,000
Direct expense - Rs 1,000
Factory/work overheads - Rs 9,750
Administrative expenditure - Rs 6.500
Selling and distribution expenses - Rs 3,250
No. of items produced - 650
Cost of raw material in stock as on 31.03.2013 - Rs 15,000
Net profit of the items is 10% of the total cost of the product

14. Calculate prime cost, works/factory cost, production cost , total cost and profit from the following data for a sewing machine manufacturer (16)
Value of stock material as on 01.04.2010 Rs 26,000
Material purchase Rs 2,74,000
Wages to labour Rs 1,20,000
Depreciation of plant and machinery Rs 8,000
Depreciation of office equipments Rs 2,000
Rent, taxes and insurance of factory Rs 16,000
General administrative expense Rs 3,400
Water, power and telephone bills of factory Rs 9.600
Water, lighting and telephone bills of office Rs 2,500
Material transportation in factory Rs 2,000
Rent of office building Rs 2,000
Direct expenses Rs 5,000
Commission and pay of salesman Rs 10,500
Repair and maintenance of plant Rs 1,000
Works manager salary Rs 30,000
Salary of office staff Rs 60,000
Value of stocks of material as on 31.03.2011 Rs 36,000
Sale of products Rs 6,36,000

15. Generalize the meaning of analytical estimating? Write its procedure, advantages, limitations and applications (16)

16. (a) A cast iron component is to be manufactured as per Fig. Estimate the selling price
per piece from the following data : (8)
Density of material = 7.2 gms/cc
Cost of molten metal at cupola spout = Rs. 20 per kg
Process scrap = 20 percent of net weight
Scrap return value = Rs. 6 per kg
Administrative overheads = Rs. 30 per hour
Sales overheads = 20 percent of factory cost
Profit = 20 percent of factory cost
Other expenditures are:
The component shown is obtained after machining the casting. The pattern which costs Rs. 5,000 can produce 1,000 pieces before being scrapped. The machining allowance is to be taken as 2 mm on each side.

(b) A lap welded joint is to be made as shown in Fig. (8)

Estimate the cost of weld from the following data :
Thickness of plate = 10 mm
Electrode diameter = 6 mm
Minimum arc voltage = 30 Volts
Current used = 250 Amperes
Welding speed = 10 meters/hour
Electrode used per meter of weld = 0.350 kgs
Labour rate = Rs. 40 per hour
Power rate = Rs. 3 per kWh
Electrode rate = Rs. 8.00 per kg
Efficiency of welding m/c = 50 percent
Connecting ratio = 0.4
Overhead charges = 80 percent of direct charges
Labour accomplishment factor = 60 percent

17. Evaluate the welding cost for a cylindrical boiler drum 2.5 m × 1 m diameter which is to be made from 15 mm thick m.s plates. Both the ends are closed by arc welding of circular plates to the drum. Cylindrical portion is welded along the longitudinal seam and welding is done both in inner and outer sides. Assume the following data: (16)
(i) Rate of welding = 2 meters per hour on inner side and  2.5 meters per hour on outer side
(ii) Length of electrodes required = 1.5 m/ meter of weld length
(iii) Cost of electrode = Rs. 0.60 per meter
(iv) Power consumption = 4 kWh/meter of weld
(v) Power charges = Rs. 3/kWh
(vi) Labour charges = Rs. 40/hour
(vii) Other overheads = 200 percent of prime cost
(viii) Discarded electrodes = 5 percent
(ix) Fatigue and setting up time = 6 percent of welding time

18. Calculate the net weight and gross weight for the component shown in Fig. Density of
material used is 7.86 gm/cc. Also calculate: (16)

(i) Length of 14 mm dia bar required to forge one component.
(ii) Cost of forging/piece if:
Material cost = Rs. 80 per kg
Labour cost = Rs. 5 per piece
Overheads = 150 percent of labour cost

19. (a) List the various elements considered while calculating the cost of a welded joint? (8)
(b) Describe: direct material cost and direct other expenses in costing of welded joint (8)

20. (a) Evaluate the cost of welding of two plates 100 × 100 × 8 mm thick to obtain a plate of dimensions 200 ×100 × 8 mm. The following data is available: (8)
(i) Welding is done on both the sides
(ii) Electrode diameter = 5 mm
(iii) Electrode used per meter of weld = 0.500 kg
(iv) Minimum arc voltage = 30 Volts
(v) Current used = 225 Amperes
(vi) Labour charges = Rs. 10/meter of weld
(vii) Electrode price = Rs. 10/kg
(viii) Efficiency of welding machine = 50 percent
(ix) Welding speed = 2 meters/hour
(x) Ratio of operating to connecting time = 1.5
(b) Evaluate the cost of filler material and gases consumed in welding of two plates 8 mm thick and 1.5 m long. Gas cutting is used to make 60°-V on the edges of both the plates. The cost of Oxygen is Rs. 10 per cu meter and cost of acetylene is Rs. 5 per cu meter. The filler rod costs Rs. 6.50/kg. Take other data from the tables. Density of filler metal is 10 gms/cc

21. Calculate the machining time to turn the dimensions shown in Fig. Starting from a m.s. bar of f 80 mm. The cutting speed with HSS tool is 60 meters per minute and feed is 0.70 mm/rev., depth of cut is 2.5 mm per pass. (16)
22. A mild steel bar 100 mm long and 38 mm in diameter is turned to 35 mm diameter. And was again turned to a diameter of 32 mm over a length of 40 mm as shown in the Fig. The bar was machined at both the ends to give a chamfer of 45° × 5 mm after facing. Calculate the machining time. Assume cutting speed of 60 m/min and feed 0.4 mm/rev. The depth of cut is not to exceed 3 mm in any operation. (16)
23. 3 A mild steel shaft, shown in Fig. 5.24 is to be turned from a 24 mm diameter bar. (16)

The complete machining consists of the following steps :
(i) Facing 24 mm f on both sides
(ii) Turning to f 20 mm
(iii) Drilling f 8 mm hole
(iv) Knurling
With H.S.S tool the cutting speed is 60 m/min. The feed for longitudinal machining is 0.3 mm/rev. The feed for facing, 0.2 mm/rev., feed for knurling 0.3 mm/rev., and feed for drilling is 0.08 mm/rev. Depth of cut should not exceed 2.5 mm in any operation. Evaluate the machining time to finish the job

24. Estimate the machining time to drill four 8 mm dia holes and one 40 mm dia central hole in the flange shown in Fig.

20 mm dia hole is drilled first and then enlarged to 40 mm f hole. Take cutting speed 10 m/min, feed for 8 mm drill 0.1 mm/rev, for 20 mm drill feed is 0.2 mm/rev. and for 40 mm f drill feed is 0.4 mm/rev.

25. (a) Estimate the time required on a shaper to machine a plate 600 mm × 1,200 mm, if the cutting speed is 15 meters/min. The ratio of return stroke time to cutting time is 2:3. The clearance at each end is 25 mm along the length and 15 mm on width. Two cuts are required, one roughing cut with cross feed of 2 mm per stroke and one finishing cut with feed of 1 mm per stroke. (8)
(b) Mild steel shaft 30 cm long is to be rough ground from 43.3 mm dia to 43 mm dia using a grinding wheel of 40 mm face width. Evaluate the time required to grind the job assuming work speed of 12 m/min and depth of cut 0.02 mm per pass. (8)
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