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Answer the following in brief ( 2 x 100) State and explain Concurrent Engineering. Simultaneous (concurrent) Engineering - A way of simultaneously designing products, and the processes for manufacturing those products, through the use of cross-functional teams to assure manufacturability and to reduce cycle time. Give an example of a design for maintenance. Design for Maintainability (DfM) is the practice of integrating operations and maintenance considerations into project planning and design to achieve effectiveness, safety, and economy of maintenance tasks during the lifespan of a facility.  For example, replacing all the fluorescent lights in an office once a year can be cheaper than replacing lights individually as they fail, because labor is used more efficiently. Since maintainability is designed in, it is important to specify both reliability and maintainability targets early in the design cycle. Differentiate between hot forging and cold forging. The cold forging manufactu...

What do you understand by intelligent robots? Intelligent robot: A robot that functions as an intelligent machine, that is, it can be programmed to take actions or make choices based on input from sensors. Third generation robots are referred to as intelligent robots. Name five commonly used unconventional machining processes. USM, ECM, EDM, LBM, AJM Name two finishing processes that can improve the finish of ground surfaces. Lapping and honing Name two advanced welding techniques. Plasma arc welding and Electron beam welding Name two investment casting processes. Full mould process and lost foam casting Define deep drawability. To form shapes with larger depth dia. ratio in sheet or strip metal by considerable plastic distortion in the dies. An example of deep drawing is the manufacture of the metallic cap of a fountain pen. What is the bathtub curve? A bathtub curve is a curve that shows, how the failure rate of a product varies with their life. What is the parting line? Parting line...

Write short notes on the following (2 x 10) Tool signature Tool signature is the description of the cutting part of the tool. There are two systems for tool signature. (i) Machine reference system (or American Standard Association system) (ASA) (ii) Tool reference system (or Orthogonal rake system) (ORS) Metal forming It is a large set of manufacturing processes in which the material is deformed  plastically to take the shape of the die geometry. The tools used for such deformation  are called die, punch etc. depending on the type of process. Recyclability Ideally, a product is designed to be recycled, reused, remanufactured, composted or biologically degraded to reduce the demand for non-renewable resources and to keep the products out of the waste stream.  Recyclability can be designed into products in terms of choice of materials and modularity. Some materials are more easily recyclable than others and facilities exist for returning them into production. For example, s...

1. Laser is produced by (a) graphite (b) emerald (c) ruby (d) diamond 2. Production of contours in flat blanks is termed as (a) blanking  (b) piercing  (c) perforating  (d) punching 3. For ferrous materials, the helix angle of a drill is taken as (a) 30⁰ (b) 45⁰ (c)  60⁰ (d)  90⁰ 4. The from rake required lo machine brass by HSS tool is (a) 15⁰ (b) 10⁰ (c) 5⁰ (d) 0⁰ 5. Porosity in thin sections of a casting can be minimized by (a) changing progressive solidification to directional solidification. (b) changing directional solidification to progressive solidification (c) use of open risers (d) providing risers with a large Area/Volume ratio. 6. Large and heavy castings are made by (a) green sand moulding. (b) dry sand moulding. (c) pressure moulding. (d) machine moulding. 7. Blanking and piercing operations can be performed simultaneously on (a) a simple die. (b) progressive die. (c) compound die. (d) combination die 8. The tolerances produced by the investment ca...

1. A standard ground drill has a point angle of (a) 90⁰  (b) 100⁰  (c) 118⁰  (d) 120⁰ 2. When the grains of a grinding wheel becomes dull, then it must be (a) replaced       (b) trued               (c) dressed            (d) treated 3. Steel cast iron pipes are cast by (a) die casting                       (b) continuous casting (c) centrifugal casting        (d) investment casting 4. Facing sand used in foundry work comprises (a) alumina, silica and clay  (b) silica and clay (c) clay and alumina              (d) silica and alumina 5. The criteria for the selection of electrode diameter in arc welding is (a) type of welding process  (b) the thickness of the components to be welded  (c) voltage used              (d) c...

1. Which one of the following is not a function of a riser? (a) to help the flow of metal towards the mould cavity (b) to provide an escape to hot gases (c) to feed the metal to the casting as it shrinks during solidification (d) to help streamline the flow of metal into a runner 2. The required cutting speed in metre/min in machining a workpiece with a diameter of 100 mm and a speed of 500 rpm will be (a) 628                       (b) 262                     (c) 157                     (d) 37.7 3. Quick return mechanism is used in (a) slotter       (b) broach                (c) milling              (d) lathe 4. The collapsible tooth-paste tubes are produced by  (a) impact extrusion          ...

Fill in the blanks. A grinding wheel is a  ⸺ cutting tool. The most commonly used material for single-point cutting tools used on the lathe is ⸺. Drawing is a language of ⸺. In gas welding, ⸺ and ⸺ are mixed. A quick return mechanism is used on ⸺ machines. In hot working, metals are heated ⸺ the recrystallization temperature. ⸺ are used on intelligent robots. To create a replica of a system, the ⸺ technique is used. Computer-aided process planning is the link between ⸺ and ⸺. AGV is a ⸺ cart. Answers abrading steel engineers acetylene, oxygen shaper above a set of high-level instructions pattern making CAD; CAM independently operated, self-propelled     ---  The study material for AMIE/B Tech/Junior Engineer exams is available at  https://amiestudycircle.com

True/ False questions from AMIE exams Moulding is earned out in moulding boxes called flasks. Taper turning means to produce a conical surface by a gradual reduction in diameter from a cylindrical workpiece. Laser beam machining is an unconventional machining process. Capstan lathe is never used on smaller work. The sand mould is an example of a permanent mould. Welding does not permit any freedom in design. Discontinuous chips are usually produced while cutting more brittle materials. The size of the shaper or planer is specified by the maximum length of stroke. Non-conductive materials can be machined by the ECM process. In the case of USM., the metal removal cost is low. Answers True True True False False True True True False True ---  The study material for AMIE/B Tech/Junior Engineer exams is available at  https://amiestudycircle.com

Friction welding Friction welding (FRW) is a solid-state welding process that generates heat through mechanical friction between workpieces in relative motion to one another, with the addition of a lateral force called "upset" to plastically displace and fuse the materials. The function of dielectric in EDM The dielectric fluid acts as an insulator between the electrode and the mould cavity. Chip breakers The function of a chip breaker is to improve chip control and reduce cutting resistance. A better balance between the two will increase the machining performance. Reverse engineering Reverse engineering is taking apart an object to see how it works in order to duplicate or enhance the object. The process often involves disassembling something (a mechanical device, electronic component, computer program, or biological, chemical, or organic matter) and analyzing its components and workings in detail. Quality Function Deployment Quality Function Deployment (QFD) is a structured...

Closed die forging Closed Die Forging is a forging process in which dies move towards each other and covers the workpiece in whole or in part.  The heated raw material, which is approximately the shape or size of the final forged part, is placed in the bottom die. The shape of the forging is incorporated in the top or bottom die as a negative image. Modular design Modular design. or “modularity in design”, is a design approach that subdivides a system into smaller parts called modules or skids, that can be independently created and then used in different systems. Examples of modular systems are cars, computers, process systems. solar panels and wind turbines, elevators and modular buildings. Recyclability This term refers to the ability of waste materials to be captured and separated from the waste stream for conversion into a new item or reused in the same capacity. Flash in forging operation The formation of metal flash is an important part of impression die-forging manufacture. ...

Gantry robots A gantry robot consists of a manipulator mounted onto an overhead system that allows movement across a horizontal plane.  Sensors A sensor is an object whose purpose is to detect events or changes in its environment and then provide a corresponding output. A sensor is a type of transducer: sensors may provide various types of output, but typically use electrical or optical signals. For example, a thermocouple generates a known voltage (the output) in response to its temperature (the environment). Casting defects A casting defect is an undesired irregularity in a metal casting process. Some defects can be tolerated while others can be repaired, otherwise, they must be eliminated. They are broken down into five main categories: gas porosity, shrinkage defects, mould material defects, pouring metal defects, and metallurgical defects. Various methods of heat treatment of steels Various types of heat treatment processes are: (a) Annealing (b) Normalizing (c) Hardening (d) ...

AGVs All automated guided vehicle or automatic guided vehicle (AGV) is a mobile robot that follows markers or wires on the floor or uses vision, magnets, or lasers for navigation. They are most often used in industrial applications to move materials around a manufacturing facility or warehouse.  Name fusion welding processes  Manual Metal Arc (MMA) Submerged arc welding (SAW) Metal inert gas (MIG) Tungsten inert gas (TIG) Laser Electron beam Significance of re-crystalline temperature  Recrystallization is a process by which deformed grains are replaced by a new set of defects-free grains that nucleate and grow until the original grains have been entirely consumed. Recrystallization is usually accompanied by a reduction in the strength and hairiness of a material and a simultaneous increase in ductility. Thus, the process may be introduced as a deliberate step in metals processing or may be an undesirable by-product of another processing step. The most important industrial...

Explain the following. Welding Welding: Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing fusion, which is distinct from lower temperature metal-joining techniques such as brazing and soldering, which do not melt the base metal, hi addition to melting the base metal, a filler material is often added to the joint to form a pool of molten material (the weld pool) that cools to form a joint that can be as strong, or even stronger, than the base material. Pressure may also be used in conjunction with heat, or by itself, to produce a weld. CNC Computer Numeric Control (CNC) is the automation of machine tools that are operated by precisely programmed commands encoded on a storage medium as opposed to controlled manually by hand wheels or lever's or mechanically automated by cams alone. Most NC today is computer (or computerized) numerical control (CNC). in which computers play an integral part of the control. Heat treatment ...

Name two allied welding processes. Brazing and soldering Tool signature Tool signature is the description of the cutting part of the tool. There are two systems for tool signature. (i) Machine reference system (or American Standard Association system) (ASA) (ii) Tool reference system (or Orthogonal rake system) (ORS) Database Management System (DBMS)  A database management system (DBMS) is system software for creating and managing databases. The DBMS provides users and programmers with a systematic way to create, retrieve, update and manage data. A DBMS makes it possible for end-users to create, read, update and delete data in a database. The DBMS essentially serves as an interface between the database and end-users or application programs, ensuring that data is consistently organized and remains easily accessible. Hot and cold working of metals  The metal working processes are derived into hot working and cold working processes. The division is on the basis of the amount of h...

Define deep drawability. To form shapes with larger depth dia. ratio in sheet or strip metal by considerable plastic distortion in the dies. An example of deep drawing is the manufacture of the metallic cap of a fountain pen. What is a bathtub curve? A bathtub curve is a curve that shows, how the failure rate of a product varies with their life. What is the parting line? Parting line (Parting surface): It is the interface that separates the cope and drag halves of a flask. What is the significance of recrystallisation temperature in metal forming? Hot-working is done at a temperature above recrystallisation temperature. Therefore, it can be regarded as a simultaneous process of deformation and recovery. What is manufacturing logic? Manufacturing logic: Dictionary meaning of logic is solving complex problems through the repeated use of simple functions that define basic concepts. Manufacturing logic is solving complex manufacturing process problems using scientific principles and lo...

Write briefly about mould wash. Mould wash: A coating applied in liquid form to walls of a mould cavity. What is adaptive control? Adaptive control: Adaptive control is a set of techniques that permit to adjust the value of control parameters in real-time, permitting to monitor of controlled variables even if plant parameters are unknown or if they change over time. This control is a special kind of non-lineal control, and the process can be split into two timelines: rapid time (feedback loop) and slow time (variation of control parameters, which affects automation). What do you understand by the term machinability index? The machinability index is used to compare the machinability of different materials in the various cutting process. It is an attempt to quantify the relative machinability of different materials. What is tack weld? Tack Welding is basically a temporary weld performed during the Fitting of a part. This is done to ensure dimensional stability before actual...