QUESTION PAPER
Department Cost Engineering
Max. Marks: 50
Problem 1: Estimate the time taken to manufacture a bolt as shown in fig. from mild
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steel bar 10.7 cm long & 20 mm diameter. Assumed
1.
2.
3.
4.
5.
6.
Feed for all turning operations
= 0.16 mm/rev.
Cutting speed for turning
= 20 meters / min
Cutting speed for threading
= 12 meters / min
Depth of cut not to exceed 3 mm in any operation
Numbers of cuts taken for threading
=5
Pitch of thread
= 2mm
Problem 2. Estimate the finish weight, raw weight & gross weight in the forged
component given below. Material of the component is 20 [Link] dimensions are in mm.
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Problem 3. Calculate the material weight of the component as given below. Also
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prepare the process sequence & cycle time sheet. Material is CRC sheet
Problem 4:
Find the time required to turn 2.5 cm dia bar to the dimensions shown
in figure. Cutting speed shall be 13.5 meter per minute and feed 16 mm per min. All cuts
shall be 3.125 mm deep.
Problem 5: Estimate the time required for tapping the hole with 2 cm dia tap
(3 mm pitch) to the depth of 5 cm in mild steel .The return speed of the tap is
to be 3 times the cutting speed which is to be 10 meters per minute.
(10)
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ANSWERS TO PROBLEMS
SOLUTION 1. First of all calculate the time required to face both the ends.
Thus,
S= 20 meters/minute
D=20 cm.
r.p.m. = 100S
D
= 100*20
* 2
= 318
Length of the cut
= D = 2 = 1 cm
2
2
Thus time required for facing both the ends
= 2* Length of the cut mt.
r.p.m * feed/rev.
= 2* 1 *10 = 0.39 mt.
318*0.16
2nd operation. Turning mild steel from 20 mm dia to 12.7 mm dia for a length of
6.5+3.5=10 cm. As depth of cut is not to exceed 3 mm so, the turning operation will be
completed in two cuts, first one of 3 mm depth and the second one of 0.65 mm depth.
Again
Thus
Length of cut
S= 20 meters/minute
D=2.0 cm.
r.p.m= 318 r.p.m.
= 6.5+3.5= 10.0 cm.
Feed= 0.16 mm/rev.
Thus time taken for the 1st cut
= 10 * 10 = 1.96 minutes.
318*0.16
For second cut
Thus
S= 20 mts/min.
D= 2.0 -- 2 * 0.3
= 1.4 cm
r.p.m= 100 *S = 100*20 = 455 r.p.m.
*D
*1.4
Length of cut
= 10.0 cm
Feed= 0.16 mm/rev
Thus, time taken for the second cut = Length of cut = 10*10 = 1.37 minute
r.p.m* feed/rev 455*0.16
Total time taken for turning= 1.96+1.37= 3.33 minutes
Next step is the threading operation
Here
S= 12 meter/min.
d=12.7 mm= 1.27 cm
Thus
r.p.m= 100*S = 100*12 = 300
*d
* 1.27
Pitch
Length of pitch
= 2 mm
= 3.5 cm
Thus time taken for one cut = 3.5 * 10 = 0.0583 minutes
300 * 2
Time taken for the 5 cuts = 5 * 0.0583 = 0.2915 minutes
Total machining time for the bolt = 0.39+3.33+0.29
= 4.01 minutes Ans
SOLUTION 2. Let us consider the bars joined are made up of 4 fragmented bars as
A, B, C, D respectively from right to left.
1. Calculation for finish weight
Thus net volume = Vol. of A + Vol. of B + Vol. of C + Vol. of D
Volume of portion A = * (12.5)2 * 61.25
4
= 7518 [Link]
Volume of portion B = * (20)2 * 25
4
= 7857 cu. mm
Volume of portion C = * (25)2 * 25
4
= 12,280 cu. mm
Volume of portion D = * (45)2 * 18.75
4
= 29,840 cu. mm
Total volume
= 7518+7857+12280+29840
= 57,495 cu. mm
The material 20MnCr5 is mild steel whose density is 7.85 gm/cm3.
Thus net weight
= 57495 * 7.85
1000
= 452.3 gm. i.e. 4.523 kg Ans.
2. Calculation for Gross weight
Considering the machining allowance on component
i). Flash losses. Let the flash be 3 mm thick and 12.5 mm wide.
Then volume of the flash = {2*(18.75+25+25+61.25) +45*12.5}*3*12.5
= 317.5*3*12.5 = 10,860 mm3
ii).
SOLUTION 5.
Cutting Speed
S = 10 meters/minute.
Diameter
D = 2 cm.
Thus
r.p.m = 100*S = 100*10 = 159
*D *2
Now the time taken for tapping
=
L
pitch* r.p.m
= 5 * 10
3 * 159
= 50
477
= 0.105 minutes
Return time
Thus Total time
= 0.105
3
= 0.035 minutes.
= Time for tapping + Return time
=
=
0.105 + 0.035
0.140 minutes Ans.
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