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Reg.No.

II SEM. M. TECH. (MFG. TECH. & ENGG.) DEGREE END SEMESTEREXAMINATIONS MAY 2010

SUBJECT: DESIGN FOR MANUFACTURING (MME-651.2)REVISED CREDIT SYSTEM

( 20 / 5 / 2010)Time: 3 Hours. MAX.MARKS: 50

1A) What are the different manufacturing related factors which influencethe design of a component. Explain with examples. (04)

1B) In extrusion, variations from flatness of long sections are reduced if ribsare added to the sections. Justify with sketch. (03)

1C) Explain with sketch at least two design recommendations forcenterless ground parts. (03)

2A) A steel shaft of diameter 40 mm and length 215 mm, has reduceddiameter of 30 mm for a length of 16 mm, to facilitate bearingmounting, on both ends of the shaft. A rectangular key of 12 x 8 mm &30 mm length is used to mount a gear on the shaft. Prepare theproduction drawing of the shaft. (04)

2B) Explain with sketch any three design guidelines for stamping duringpiercing of holes. (03)

2C) Sketch a proportionate I section to be produced by forging operation.Discuss the reason for proportionate dimension of web and rib. Alsoindicate the parting line. (03)

3A) Mention the sequence of operations followed for manufacturing ofmachine tool spindle. Explain the significance of each step involved. (07)

3B) Recommend one each design guideline for manufacturing of partsproduced by planning, shaping and slotting machine. (03)

MANIPAL INSTITUTE OF TECHNOLOGYManipal University, Manipal 576 104

Instruc tions to Candidates: Answer ANY FIVE FULL questions. Assumptions if any made must be clearly mentioned.

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4A) The vertical leg of a L shaped bracket having two ribs, is used tosupport a shaft end. The bracket is mounted on a horizontal surfacewith the help of 4 screws. Design the bracket for manufacturing underthe following initial manufacturing conditions. Explain the design formanufacturing of bracket and also prepare production drawing for both.

i) as cast ii) as fabricated (07)

4B) Explain with sketch any three design recommendations for drillingoperation. (03)

5) Explain the following in brief

i) Design of wide sections in roll-formingii) Manufacturing sequence affect component designiii) Design recommendations for the selection of raw materialsiv) Whlie machining a keyway in a shaft, flat ends are avoidedv) Heat treatment to be followed by grinding (10)

6A) Discuss providing radius, undercuts & gear teeth in powder metallurgyparts from manufacturing consideration. (04)

6B) The Fig. Q6B shows the assembly and part drawing of a MillingFixture. This is an indexing fixture designed to hold a thrust washer(part no. 12) while milling four slots at right angles to each other on oneof its flat faces. Holding and releasing of the thrust washer are carriedout as follows.

With the knob held loose on the taper bolt, the thrust washer is placedon the index block so as to surround the collar of the collet holder.Then the knob on the taper bolt is tightened. This draws the collet tomove down against the spring pressure. This will cause the colletholder to expand and grip the washer from inside. After machining, theknob is turned loose on the taper bolt which in turn allows the collet tomove up by the action of the spring. When the collet is moved up, itreleases the expanding pressure on the collet holder which releasesthe thrust washer. After two slots are cut in one setting, indexing blockis swung by 90 o

(06)

(as shown in top view of the assembly drawing) to cut

the other two slots.Prepare the production drawing of Base block. Why 20 x 6 mm slot isprovided in the Base block ?

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Fig. Q6B Milling Fixture

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Fig. Q6B Milling Fixture