DEPARTMENT OF ROBOTICS AND AUTOMATION

Question Bank

Academic Year 2022-23

VII SEMESTER

ME8793 / PROCESS PLANNING AND COST ESTIMATION

Prepared by

Prof. Dr. A. MUNIARAJ

 UNIT – I INTRODUCTION TO PROCESS PLANNING

PART-A (2
Marks)
BT
Q.N
Questions Competenc
o Level

1. Identify the process planning activities. BT- Rememberi

1
2. Select the process parameters for setting machines and toolings. BT- Applying
3
3. Summarize the factors influencing process selection. BT- Understandi
2
4. List the advantages of Standardization BT- Understandi
2
5. Define process planning. BT- Rememberi
1
BT-
6. Summarize the use of drawings interpretation. Understandi
2
BT-
7. Quote the each component of the product in the process sheet. Rememberi
1
8. Define batch production. BT- Rememberi
1
9. Compare mass and batch production. BT- Understandi
2
10. What is meant by reliability of the product? BT- Understandi
2
PART-B (8 Marks)
BT
Q.No Questions Mark
Level Competen
s
Identify the steps involved in Process Design and also examine
1. 8 BT-1 Remember
the basic factors affecting Process Design.
g
Explain the technological frame work of process planning
2. 8 BT-4 Analyzin
by using a block diagram.
Explain the procedure involved in the product design with
3. 8 BT-1 Remember
suitable flow chart.
g
Devise with neat sketch and the steps followed for
4. 8 BT-4 Analyzin
material selection process and methods.
Show the two approaches to Process Planning in the context Remember
5. 8 BT-1
of CAPP (Computer Aided Process Planning)? g
Understandi
6. Classify the four distinct processing strategies. 8 BT-2
g
Identify and describe at least five types of geometrical 8 Rememberin
7. BT-1
tolerances. g
Understandi
8. Summarize the process layout with neat sketch. 8 BT-2
 UNIT – II PROCESS PLANNING ACTIVITIES
PART-A(2Marks)
Q.N Questions BT Competence
o Level
1. List the factors Considered for selecting Process parameter. BT-1 Remembering

2. Classify milling operations. BT-2 Understanding

3. Define cutting speed. BT-1 Remembering

Solve the general factors that will influence the design construction of a
4. BT-3 Applying
work holder.
A planer is capable of 15 strokes per minute over a stroke length of 2m.
5. BT-1 Remembering
The cutting time ratio for the machine is 4:3. Determine cutting speed.

6. Classify the three basic functions of Jig. BT-2 Understanding

7. Show the main reasons for the use of jigs and fixtures. BT-1 Remembering

8 List the types of clamping devices. BT-2 Understanding

9 Show the main reasons for the use of jigs and fixtures. BT-1 Remembering

10 Assess the three elements of Direct cost BT-1 Remembering

PART-B
(8Marks) BT
Q.N Mark
Questions Competence
o s Level
Summarize the general recommendations for cutting depths
1. For turning, boring, milling and Drilling? BT-
8 Understanding
2
Describe depth of cut and what are the most important factors
2. that
affect the depth of cut possible when machining? 8 BT- Remembering
1
For the part shown in Fig.iv calculate the maximum
surface
speeds for facing, turning all surfaces and parting off.
The maximum spindle speed of the lathe being used is 600rpm.

3.

BT-3 Applying

Fig.iv
Show the seven quality control tools and techniques relate to
4. quality improvement and problem solving? 8 BT-2 Understanding
 5 Compare the process control and process capability. 8 BT-2 Understanding
Explain the typical quality characteristics are measured in
6 8 BT-2 Understanding
quality control

7 Compare the measuring variables and attributes 8 BT-2 Understanding

UNIT III- INTRODUCTION TO COST ESTIMATION

PART-
A(2Marks)
Q.N Questions BT Competence
o Level
1. Define cost accounting. BT- Remembering
1
2. Distinguish between cost estimation and cost accounting. BT- Understanding
2
3. List the types of estimates. BT- Remembering
1
4. Classify the sources of cost estimation? BT- Understanding
2
5. What is meant by “conceptual cost estimating”? BT- Remembering
1
6. What is the accuracy expected in conceptual cost estimates? BT- Understanding
2
7. Point out any two objectives of cost estimation. BT- Understanding
2
8. Summarize batch costing. BT- Understanding
2
9. Describe briefly standard data. BT- Remembering
1
10. Define under estimate. BT- Remembering
1
PART-B (8
Marks) BT
Q.N
Questions Mark Competence
o L
s
eve
l BT-
1. Give the advantages of cost accounting. 8 Understanding
2
8 BT-
2 Discuss the objectives of cost estimation Understanding
2
3. With suitable application examples classify costs. 8 BT- Applying
3
4. Discuss various types of estimates 8 BT- Understanding
2
5. Explain the data requirements for cost estimation. 8
BT- Understanding
6. Describe the different methods of estimates.. 8 2
BT- Understanding
2
7. Explain the allowances in estimation 8
BT- Understanding
2
 UNIT IV PRODUCTION COST ESTIMATION
PART-A(2Marks)

Q. Questions BT Competence
No Level
1. What is meant by production cost. BT-2 Understanding
2. How do you estimate the time required for forging?
BT-2 Understanding
3. Explain the actual welding costs involved in estimation in welding shop? BT-1 Remembering
4. List the losses to be considered in estimating the gross weight of a forging
component. BT-1 Remembering
5. Write the different sections in forging shop. BT-1 Remembering
6. What meant by welding. BT-2 Understanding
7. Write the difference between gas and arc welding. BT-1 Remembering
8. Define press forging. BT-1 Remembering
9. Illustrate how to estimate the gas cutting costs
BT-1 Remembering
10. Give the losses in forging process. BT-2 Understanding

PART-B (13 Marks)

Q. Questions
No BT
Marks Competence
Le
vel
Explain the estimate procedure for the material cost involved in
1 the 8 BT-3 Applying
manufacturing
Calculate a casting.
the total cost of CI (Cast Iron) cap shown in Fig, from
the following data :
Cost of molten iron at cupola spout = Rs. 30 per kg
Process scrap= 17 percent of net wt. of casting
Process scrap return value= Rs. 5 per kg
Administrative overhead charges= Rs. 2 per kg of metal poured.
Density of material used= 7.2 gms/cc.

2
8 BT-3 Applying

3 A cast iron component is to be manufactured as per Fig.ii Estimate

the selling price per piece from the following data
: 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
8 BT-4 Analyzing
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.

4 8 BT-4 Analyzing

A lap welded joint is to be made as shown in Fig. Estimate the

cost of weld from the following data :

Thickness of plate= 10 mm
Electrode diameter= 6 mm
Minimum arc voltage= 30
5. Volts Current used= 250 8 BT-4 Analyzing
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
Connecting ratio= 0.4
Efficiency of welding m/c= 50 percent
 Overhead charges = 80 percent of direct charges
Labour accomplishment factor = 60 percent

A container open on one side of size 0.5 m × 0.5 m × 1 m is to be

fabricated from 6 mm thick plates Fig.. The plate metal weighs
8 gms/cc. If the joints are to be welded, make calculations for
the cost of container. The relevant data is:
Cost of plate= Rs. 10 per kg
Sheet metal scarp (wastage) = 5 percent of material
Cost of labour = 10 percent of
sheet metal cost
Cost of welding material= Rs. 20 per meter of weld.

6.
8 BT-3 Applying

Calculate the cost of welding two plates 200 mm × 100 mm × 8

mm thick to obtain a piece 200 mm × 200 mm × 8 mm
approximately using rightward welding technique Fig.

The following data is available:

Cost of filler material= Rs. 60 per kg
7.
Cost of oxygen= Rs. 700 per 100 cumeters
13 BT-5 Evaluating
Cost of acetylene= Rs. 700 per 100
cumeters Consumption of oxygen= 0.70 cu
m/hr Consumption of acetylene= 0.70 cu
m/hr
Diameter of filler rod= 4 mm
Density of filler material= 7.2 gms/cc
. Filler rod per meter of weld= 340
cms Speed of welding= 2.4 meter/hr
 Labour is paid Rs. 20 per hour.
overheads may be taken as100 percent of labour cost.

UNIT-V MACHINING TIME CALCULATION

PART-A(2Marks)
Q.N Questions BT Competence
o 1. Level
Define cycle time. BT-1 Remembering
2. List various factors affecting cutting speed. BT-1 Remembering
3. Write formula to calculate the time required for drilling a hole in an BT-2 Understanding
object.
4. Estimate the milling time to cut 60 teeth on a gear blank 60 mm thick;
feed BT-2 Understanding
5. 35 mm/min and take overall set up time as 10 minutes.
Calculate the time required for turning operation. BT-3 Applying
6. List the major objectives in machining industries? BT-1 Remembering
7. Discuss briefly about the necessities to determine the actual
machining time? BT-1 Remembering
8. List the major factors to be considered for selecting cutting velocity
for machining operations? BT-1 Remembering
9. List the major factors to be considered for selecting value of feed
For machining operations? BT-1 Remembering

10. Define machining time. BT-1 Remembering

 PART-B (8 Marks)

BT
Q.
Questions Mark
No Le Competence
s
1. Calculate the machining time to turn the dimensions shown in vel
Fig.
Starting from a M.S. bar off 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.

8 BT- Applying
3

2. A mild steel bar 100 mm Fig i long and 38 mm in diameter is

turned to 35 mm dia. And was again turned to a diameter of
32 mm over a length of 40 mm as shown in the Fig.ii. 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.

8 BT-3 Applying

3. A mild steel shaft, shown in Fig.iii is to be turned from a

24 mm dia bar.

13 3
BT- Applying
 A mild steel shaft, shown in Fig.iii is to be turned from a 24
mm
dia
bar.

The complete machining consists of the following

steps : (i) Facing 24 mm on both sides
(ii) Turning to 20 mm
8 BT-3 Applying
(iii) Drilling 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
4. operation. Evaluate
Estimate the the machining
machining time to finish
time required producetheone
job.piece of
the
component shown in Fig. Starting from 25 mm bar. The
following data is available.

For turning:
Cutting speed = 40 m/min.
Feed = 0.4 mm/rev. 8 BT- Evaluating
5
Depth of cut = 2.5 mm/per
pass
For thread cutting:
Cutting speed = 8 m/min.

5. Estimate the time taken to drill a 25 mm dia × 10 cm deep hole in

a
casting. First a 10 mm dia drill is used and then the hole is 8 BT-5 Evaluating
enlarged by a 25 mm dia drill. Assume:

Cutting speed= 15 m/min.

Feed for 10 mm drill= 0.22
mm/rev. Feed for 25 mm drill=
0.35 mm/rev.
6.
Estimate the machining time to drill four 8 mm dia holes and
one
40 mmdia central hole in the flange shown in Fig. v. 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 of drill feed is 0.4
mm/rev.

8 BT-4 Analyzing

7. (a) Analyse the time required to tap a hole with 25 mm dia tap
to a
length of 30 mm having 3 threads per cm. The cutting speed is
10 m/min. For return stroke the speed is 2 times the cutting speed.
(b) A 300 mm × 50 mm rectangular cast iron piece is to be face 8 BT- Applying
milled with a carbide cutter. The cutting speed and feed are 50 3
m/min and 50 mm/min. If the cutter dia is 80 mm and it has
12
cutting teeth, calculate:
(i) Cutter R.P.M
(ii)
(iii)Feed per time
Milling tooth