BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE, PILANI

ME F112: Workshop Practice

Comprehensive Examination: Closed Book
Max Marks: 80 Duration: 120 min. Date: 26th Feb, 2021

No partial marks for theory questions

Q1.
An operator want to cut a T-slot throughout in the workpiece
along the length as shown in the figure on a vertical milling
machine. The length of the workpiece is 150 mm. The tools
available with the operator are; a center drill bit of 20 mm
diameter, plain milling cutter with 15 teeth, T-slot milling
cutter with 20 teeth and end milling cutter with 5 teeth. The
feed is 0.10 mm/tooth for milling and 0.20 mm/rev. for drilling. Milling operation is done at cutting speed of 25
m/min and drilling at 20 m/min. Ignore all the approach and over-travel distances and assume each operation is
performed in a single pass. Determine the minimum time to machine the slot. [20]

Sol:
Step-1 :End Milling Cutter [3]

Length of workpiece = 150mm , Z = 5, f = 0.10 mm/tooth, v = 25 m/min, D = 20 mm

𝜋𝐷𝑁
𝑉= [2]
1000

1000×25
𝑁= = 𝟑𝟗𝟕. 𝟖𝟖 RPM [3]
𝜋×20

𝐿 150
𝑡1 = = = 𝟎. 𝟕𝟓𝟑𝟗 min [2]
𝑓×𝑍×𝑁 0.1×5×397.88

Step-2: T-slot milling cutter [3]

Length of workpiece = 150mm, Z = 20, f = 0.10 mm/tooth, v = 25 m/min, d = 50mm

1000×25
𝑁= = 𝟏𝟓𝟗. 𝟏𝟓𝟒 RPM [3]
𝜋×50

𝐿 150
𝑡2 = = = 𝟎. 𝟒𝟕𝟏𝟐 min [2]
𝑓×𝑍×𝑁 0.1×20×159.154

Total time = 𝒕𝟏 + 𝒕𝟏 = 𝟎. 𝟕𝟓𝟑𝟗 + 𝟎. 𝟒𝟕𝟏𝟐 = 𝟏. 𝟐𝟐𝟓 min [2]

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Q2.
a)
A shaper machine tool operating at 120 strokes per minute is used to machine a work piece of size 250 mm × 120
mm × 32 mm. The clearance at each end is 12.5 mm, feed = 0.6 mm/stroke, depth of cut = 2 mm, Maximum
available length of stroke = 170 mm. If the forward stroke is completed in 2300, then determine:
i) Minimum time (in minutes) required to reduce the thickness of work piece to 30 mm in a single pass [6]
ii) Cutting speed in m/min [6]
3
iii) Material Removal Rate in mm /min [3]

Sol: N = 120, C = 12.5mm, f= 0.6mm/stroke, d = 2mm,

Max Length of stroke = 170 mm, Width (w) = 250mm

𝑤 250
i) 𝑇𝑚 = 𝑓𝑁 = 0.6×120 = 𝟑. 𝟒𝟕𝟐 min [6]

ii) Length of stroke = 120+2*C = 120+2*12.5 = 145mm [2]

130
𝑚 = = 0.565 [2]
230

𝑁𝐿(1+𝑚) 120×145(1+0.565)
𝑣= = = 𝟐𝟕. 𝟐𝟑 m/min [2]
1000 1000

iii) MRR = vfd

= (27.23 × 1000) × 0.6 × 2 = 𝟑𝟐𝟔𝟖𝟏. 𝟕𝟒 𝒎𝒎𝟑 /𝒎𝒊𝒏 [3]

b)
Recommend the characteristics of a grinding wheel for rough grinding of mild steel to an operator. Justify your
recommendation. [5]

Sol:

Grain size or grit, Grade, Structure [2]

i. Grain size: Large (Coarse), for rough grinding or poor surface finish and higher MRR [1]

ii. Grade: Hard, because hard wheel is used for soft materials [1]

iii. Structure: Open, because continuous chips are produced [1]

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Q3.
A 20 mm thick plate is to be rolled into a 4 mm thick sheet in a four stand continuous rolling mill. All rolls have
equal diameters. Assume equal reduction in each stand by adjusting the gap between rollers, and coefficient of
friction is 0.14.
i) Find the diameter of rolls. [5]
ii) Assume no change in the width of sheet, determine the velocity of final rolled sheet if the feed velocity of
20 mm thick plate is 5 m/min. [5]

Sol:

Initial thickness = 20, Final thickness = 4, No. of stands = 4, 𝜇 = 0.14

i) Reduction in thickness at each stand = (20-4)/4 =4mm
Thickness (t2) after stand 1 = 20-4 = 16
Thickness (t2) after stand 2 = 16-4 = 12, so t3 = 8 and t4 = 4mm
Max. draft=𝜇 2 𝑅
4
𝑅 = (0.14)2 = 204.081, Diameter = 408.163mm [5]

OR

0.14 =tan alpha

Alpha = 7.9696
𝛿𝑡 4
𝐶𝑜𝑠𝛼 = 1 − = 1 − 𝐷 = cos 7.9696
𝐷

Diameter = 414.53 mm [5]

ii) AiVi =A1V1 =A2V2 =A3V3 =A4V4

20×5
V4 = (AiV1)/A4= = 25m/min [5]
4

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Q4.
A work piece shown in figure below is to be made from the casting process. [10]

i) Show the direction of solidification (using arrows) inside casting. Justify your direction
ii) In which portion of the workpiece shrinkage cavity are likely to be formed, if riser is not provided. Justify
your answer.
iii) Do you think the above work piece needs a riser? If yes, then suggest a suitable position for placing the riser.
If no, why it is not required? Justify your answer.

Sol:

i) Solidification should start from thinnest section and proceed towards the thickest section progressively moving
towards the riser and simultaneously solidification will occur from outer to inner portion. [2]

Shown in figure below.

[2]

ii) Section 3 [2]

Section 3 of the part, being larger in size will be last one to solidify. Section-3 feeds molten metal to section 1
and 2 due to shrinkage which take place in these two parts. Hence liquid metal is not available for filling
cavities in section-3, during its solidification leaving behind a shrinkage void. [2]

iii) shrinkage cavity is developed in section-3 of the casted product and this can be avoided by placing a riser
above section-3. [2]

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Q5.
An operator want to weld two thicker mild steel sheets. Recommend your selection out of following. Justify your
recommendation.
i) Forehand welding / Backhand Welding [4]
ii) Direct current straight polarity / Direct current reverse polarity [4]
iii) Arc welding / Gas welding [2]

Sol:

i) Backhand Welding [1]

Because heat is concentrated into metal, so thicker parts can be welded. [3]

ii) Direct current straight polarity [1]

Because more heat flows from electrode to the workpiece and more weld penetration is achieved to weld thicker
plates. [3]

iii) Arc Welding

Because, more heat is required to melt thicker parts and more heat is produced in arc welding [2]

Q6.
i) Which kind of pattern you will recommend for producing casting with projections or undercuts? Justify. [4]
ii) Which cold forming process you will recommend for reducing the uniform cross section area of a cast iron cube?
Justify. [4]
iii) How do you identify which part is drag half and which part is cope half in a split pattern? [2]

Sol:
i) Loose Piece Pattern [2]

Because, projected part can be withdrawn first and then the main pattern to get the desired shape. [2]

ii) Cold forming is not possible [2]

because cast iron is a brittle material, hence cold forming is not recommended.

iii) Cope has the dowel pins while drag has the holes [2]

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