# Recent questions and answers in Materials, Manufacturing and Industrial Engineering

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Bars of $250$ mm length and $25$ mm diameter are to be turned on a lathe with a feed of $0.2$ mm/rev. Each regrinding of the tool costs Rs. $20$. The time required for each tool change is $1$ min. Tool life equation is given as $VT^{0.2} = 24$ (where ... /min and tool life $T$ is in min). The optimum tool cost per piece for maximum production rate is Rs. _______ (round off to $2$ decimal places).
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For a single item inventory system, the demand is continuous, which is $10000$ per year. The replenishment is instantaneous and backorders ($S$ units) per cycle are allowed as shown in the figure. As soon as the quantity ($Q$ units) ordered from the ... year. Based on the total cost minimization criteria, the maximum inventory reached in the system is ________ (round off to nearest integer).
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In an orthogonal machining with a single point cutting tool of rake angle $10^{\circ}$, the uncut chip thickness and the chip thickness are $0.125$ mm and $0.22$ mm, respectively. Using Merchant’s first solution for the condition of minimum cutting force, the coefficient of friction at the chip-tool interface is _______ (round off to two decimal places).
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The crystal structure of $\gamma$ iron $\text{(austenite phase)}$ is $BCC$ $FCC$ $HCP$ $BCT$
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The base of a brass bracket needs rough grinding. For this purpose, the most suitable grinding wheel grade specification is $C30Q12V$ $A50G8V$ $C90J4B$ $A30D12V$
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In the Critical Path Method $(CPM)$, the cost-time slope of an activity is given by $\dfrac{\text{Crash Cost – Normal Cost}}{\text{Crash Time}} \\$ $\dfrac{\text{Normal Cost}}{\text{Crash Time – Normal Time}} \\$ $\dfrac{\text{Crash Cost}}{\text{Crash Time – Normal Time}} \\$ $\dfrac{\text{Crash Cost – Normal Cost}}{\text{Normal Time – Crash Time}}$
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A sheet metal with a stock hardness of $250\: HRC$ has to be sheared using a punch and a die having a clearance of $\text{1 mm}$ between them. If the stock hardness of the sheet metal increases to $400\: HRC$, the clearance between the punch and the die should be _________ $mm.$
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A company is hiring to fill four managerial vacancies. The candidates are five men and three women. If every candidate is equally likely to be chosen then the probability that at least one woman will be selected is _______(round off to $2$ decimal places).
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A strip of thickness $40\:mm$ is to be rolled to a thickness of $20\:mm$ using a two-high mill having rolls of diameter $200\:mm$. Coefficient of friction and arc length in $mm$, respectively are $0.45\:\text{and}\:38.84$ $0.39\:\text{and}\:38.84$ $0.39\:\text{and}\:44.72$ $0.45\:\text{and}\:44.72$
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For an assembly line, the production rate was $4$ pieces per hour and the average processing time was $60$ minutes. The $\text{WIP}$ inventory was calculated. Now, the production rate is kept the same, and the average processing time is brought down by $30$ percent. As a result ... time, the $\text{WIP}$ inventory decreases by $25\%$ increases by $25\%$ decreases by $30\%$ increases by $30\%$
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A slot of $25\:mm\times 25\:mm$ is to be milled in a workpiece of $300\: mm$ length using a side and face milling cutter of diameter $100\: mm$, width $25\: mm$ and having $20$ teeth.For a depth of cut $5\: mm$, feed per tooth $0.1\: mm$, ... $5\: mm$ each, the time required for milling the slot is ________ minutes (round off to one decimal place).
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The following data applies to basic shaft system: tolerance for hole$= 0.002\: mm$, tolerance for shaft$= 0.001\: mm$, allowance $= 0.003\: mm$, basic size $= 50\: mm$. The maximum hole size is _______ $mm$ (round off to $3$ decimal places).
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A steel part with surface area of $125\:cm^{2}$ is to be chrome coated through an electroplating process using chromium acid sulphate as an electrolyte. An increasing current is applied to the part according to the following current time relation: $I=12+0.2t$ ... $\mu m$ (round off to one decimal place).
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In a turning process using orthogonal tool geometry, a chip length of $100\: mm$ is obtained for an uncut chip length of $250\: mm$. The cutting conditions are: cutting speed $= 30\: m/min$, rake angle $= 20^{\circ}$. The shear plane angle is _______ degrees (round off to one decimal place).
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The thickness of a steel plate with material strength coefficient of $210\: MPa$, has to be reduced from $20\: mm$ to $15\: mm$ in a single pass in a two-high rolling mill with a roll radius of $450\: mm$ and rolling velocity of $28\: m/min$. If the plate has ... places). Note: $\text{Average Flow Stress = Material Strength Coefficient}\times \dfrac{\left (\text{True Strain} \right )^{n}}{(1+n)}$
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Two business owners Shveta and Ashok run their business in two different states. Each of them, independent of the other, produces two products $A$ and $B$, sells them at $Rs.\:2,000$ per kg and $Rs.\:3,000$ per kg, respectively, and uses Linear ... absolute value of the difference in daily (optimal) revenue of Shveta and Ashok is _________ thousand Rupees (round off to $2$ decimal places).
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$\textbf{Consider two cases as below.}$ $\textbf{Case 1:}$ A company buys $1000$ pieces per year of a certain part from vendor $'X'.$ The changeover time is $2$ hours and the price is $Rs.\: 10$ per piece. The holding cost rate per part is $10\%$ per year. ... percentage reduction in the annual cost of $\text{Case 2}$, as compared to $\text{Case 1}$ is __________ (round off to $2$ decimal places).
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Hardenability of steel is a measure of the ability to harden when it is cold worked the maximum hardness that can be obtained when it is austenitized and then quenched the depth to which required hardening is obtained when it is austenitized and then quenched the ability to retain its hardness when it is heated to elevated temperatures
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The fluidity of molten metal of cast alloys (without any addition of fluxes) increases with increase in viscosity surface tension freezing range degree of superheat
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The cold forming process in which a hardened tool is pressed against a workpiece (when there is relative motion between the tool and the workpiece) to produce a roughened surface with a regular pattern is Roll forming Strip forming Knurling Chamfering
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The most common limit gage used for inspecting the hole diameter is Snap gage Ring gage Plus gage Madter gage
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In an electrical discharge machining process, the breakdown voltage across inter electrode gap (IEG) is $200$ V and the capacitance of the RC circuit is $50 \mu F$. The energy (in $J$) released per spark across the IEG is _________
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The binary phase diagram of metals $P$ and $Q$ is shown in the figure. An alloy $X$ containing $60 \% P$ and $40 \% Q$ (by weight) is cooled from liquid to solid state. The fractions of solid and liquid (in weight percent) at $1250^o C$, respectively, will be $77.8 \% \text{ and } 22.2 \%$ $22.2 \% \text{ and } 77.8 \%$ $68.0 \% \text{ and } 38.0 \%$ $32.0 \% \text{ and } 68.0 \%$
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The activities of a project, their duration and the precedence relationships are given in the table. For example, in a precedence relationship $X<Y,Z$ means that $X$ is predecessor of activities $Y$ and $Z$ ... $17$ $21$ $23$ $25$
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The figure shows a pouring arrangement for casting of a metal block. Frictional losses are negligible. The acceleration due to gravity is $9.81 \: m/s^2$ .The time (in $s$, round off to two decimal places) to fill up the mold cavity (of size $40 \: cm \times 30 \: cm \times 15 \: cm$) is _____
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A gas tungsten arc welding operation is performed using a current of $250 \: A$ and an arc voltage of $20 \: V$ at a welding speed of $5 \: mm/s$. Assuming that the arc efficiency is $70 \%$, the net heat input per unit length of the weld will be _________$kJ/mm$ (round off to one decimal place)
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The thickness of a sheet is reduced by rolling (without any change in width) using $600 \: mm$ diameter rolls. Neglect elastic deflection of the rolls and assume that the coefficient of friction at the roll-workpiece interface is $0.05$. The sheet enters the ... possible final thickness that can be produced by this process in a single pass is __________ $mm$ (round off to two decimal places).
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A through hole is drilled in an aluminium alloy plate of $15 \: mm$ thickness with a drill bit of diameter $10$ mm, at a feed of $0.25$ mm/rev and a spindle speed of $1200$ rpm. If the specific energy required for cutting this material is $0.7 \: N \cdot m/mm^3$, the power required for drilling is ____________$W$ (round off to two decimal places)
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The annual demand of valves per year in a company is $10,000$ units. The current order quantity is $400$ valves per order. The holding cost is Rs. $24$ per valve per year and the ordering cost is Rs. $400$ per order. If the current order quantity is changed to Economic Order Quantity, then the saving in the total cost of inventory per year will be Rs. __________ (round off to two decimal places).
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In a casting process, a vertical channel through which molten metal flows downward from pouring basin to runner for reaching the mold cavity is called blister sprue riser pin hole
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Which one of the following welding methods provides the highest heat flux $(W/mm^2)$? Oxy-acetylene gas welding Tungsten inert gas welding Plasma arc welding Laser beam welding
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The length, width and thickness of a steel sample are $400$ mm, $40$ mm and $20$ mm, respectively. Its thickness needs to be uniformly reduced by $2$ mm in a single pass by using horizontal slab milling. The milling cutter (diameter: $100$ mm, width: $50$ mm) has $20$ teeth and rotates at $1200$ rpm ... machining task are $14$ mm, $18.4$ s $21$ mm, $28.9$ s $21$ mm, $39.4$ s $14$ mm, $21.4$ s
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The position vector $\overrightarrow{OP}$ of point $P(20,10)$ is rotated anti-clockwise in $X-Y$ plane by an angle $\theta = 30^{\circ}$ such that point $P$ occupies position $Q$, as shown in the figure. The coordinates $(x,y)$ of $Q$ are $(13.40,22.32)$ $(22.32, 8.26)$ $(12.32, 18.66)$ $(18.66, 12.32)$
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The table presents the demand of a product. By simple three-months moving average method, the demand-forecast of the product for the month of September is ... $490$ $510$ $530$ $536.67$
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In orthogonal turning of a cylindrical tube of wall thickness $5 \: mm$, the axial and the tangential cutting forces were measured as $1259 \: N$ and $1601 \:N$, respectively. The measured chip thickness after machining was found to be $0.3 \: mm$ ... first solution, the shear strength of the material is closest to $722 \: MPa$ $920 \: MPa$ $200 \: MPa$ $875 \: MPa$
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A circular shaft having diameter $65.00_{-0.05}^{+0.01} \: mm$ is manufactured by turning process. A $50 \: \mu m$ thick coating of TiN is deposited on the shaft. Allowed variation in TiN film thickness is $\pm 5 \mu m$. The minimum hole diameter (in mm) to just provide clearance fit is $65.01$ $65.12$ $64.95$ $65.10$
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Match the following sand mold casting defects with their respective causes. ... $P-3, Q-4, R-2, S-1$ $P-2, Q-4, R-1, S-3$ $P-3, Q-4, R-1, S-2$
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In ASA system, the side cutting and end cutting edge angles of a sharp turning tool are $45^{\circ}$ and $10^{\circ}$, respectively. The feed during cylindrical turning is $0.1 \: mm/rev$. The center line average surface roughness (in $\mu m$, round off to one decimal place) of the generated surface is __________
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Taylor’s tool life equation is given by $VT^n=C$, where $V$ is in $m/min$ and $T$ is in $min$. In a turning operation, two tools $X$ and $Y$ are used. For tool $X$, $n=0.3$ and $C=60$ and for tool $Y$, $n=0.6$ and $C=90$. Both the tools will have the same tool life for the cutting speed (in $m/min$, round off to one decimal place) of ____________
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Five jobs $(J1, J2, J3, J4$ and $J5)$ need to be processes in a factory. Each job can be assigned to any of the five different machines $(M1, M2, M3, M4$ and $M5)$. The time durations taken (in minutes) by the machines for each of the jobs, are given in the table. However, each job is assigned ...
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