VELAMMAL INSTITUTE OF TECHNOLOGY

Department of Mechanical Engineering

Process Planning and Cost Estimation

Question Bank Model Exam
Define process planning.(QB)
Select the process parameter for setting machines and toolings.(QB)
Identify the Process planning activities.(Dec-12)
Summarize the factors influencing Process selection.(Jun-12)
Give the factors that considered in Depth of Cut.(QB)
Write any two objectives of cost estimation.( Apr/May 2015)
What is batch costing?( Nov/Dec 2012)
List the factors Considered for Selecting Process parameter.(QB)
What are all the documents necessary for process planning(Jun-12)
What is computer Aided process planning(May-10)
What is meant by overhead expenses?(QB)
Define cutting speed.( Apr/May 2015)
Define cost accounting.( Apr/May 2013)
What are the types of process planning?( Apr/May 2015)
List the information required for process planning.( Nov/Dec 2014)
Define standard data.( Apr/May 2015)
List the use of Process Sheet.( Apr/May 2015)
List the objectives of Process planning.( Apr/May 2014)
What is cost accounting?(Jun-12)
What do you meant by catalogue price?(May-08)
What do you mean by multiple cost method(Dec-12)
What are the objectives of costing?(Dec-09)
What do you understand by Budgetary estimates?(May-08)
Brief about indirect material cost.(Dec-08)
What are the various elements considered while calculating the cost of a welded joint?(Dec-12)
What is fatigue allowance?(May-13)
Name a few methods of cost estimates(Jun-12)
What is meant by machine time?(Dec-11)
A manufacturing sector produces 5000 machines per year.If the total on costs during that year are
Rs.2,00,000,Calculate the overhead cost for each machine.(May-08)
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Summarize the factors are taken into consideration in Process Selection and Machine Selection?
Generalize the factors that affect tooling performance( Apr/May 2015)
Write down the step by step procedure for estimating the direct material cost.( Apr/May 2010)
Explain Different types of Pattern Allowances (Nov 2014)
Summarize the factors are taken into consideration in process selection and Machine Selection?
Describe the steps or procedures involved in Process Planning.(May-13)
(a) Explain the process planning procedure.( Apr/May 2015)
Explain the components retrieval type CAPP system with a block diagram(Dec-09)
Compare manual and computer aided process planning (Dec-09)
Describe the various types of charts and diagrams used in process planning.(Nov 2013)
Name the various elements of cost. Explain each element in detail giving suitable examples.
Show the data is listed for each component of the product in the process sheet.(May-13)
Explain with neat sketch and the steps followed for material selection process and methods.
Explain briefly the factors considered for selection of equipments for process planning?(Dec-11)
Elaborately discuss the various process planning activities(Jun-12)
Explain the components retrieval type CAPP system with a block diagram(Dec-09)
Discuss the objectives of cost estimation.
Give the advantages of cost accounting. (Dec-13)
Compare manual and computer aided process planning (Dec-09)
Explain the process planning procedure. (A/M 2015)
Calculate prime cost, factory cost, production cost, total cost and selling price per item from the data
given below for the year 2012-13 1.Cost of raw material in stock as on 1.4.2012 - Rs 25,000 2. Raw
material purchased - Rs 40,000 3.Direct labour cost - Rs 14,000 , 3.Direct expense - Rs 1,000, 5.
Factory/work overheads - Rs 9,750, 6. Administrative expenditure - Rs 6.500,7. Selling and distribution

expenses - Rs 3,250, 8. No. of items produced 650, 9. Cost of raw material in stock as on 31.03.2013
- Rs 15,000, 10. Net profit of the items is 10% of the total cost of the product(Dec-13)
22. Estimate the total cost of 20C.I flanged pipe casting shown in figure, assume the following data: Cost
of C.I = Rs. 5/kg; Cost of process scrap = Rs. 2/Kg; process scrap = 2% of net weight of casting;
Moulding and pouring charges = Rs. 2/Piece; Casting removal and cleaning = Rs.0.50/piece;
Administrative overheads = 5% factory cost; Selling overheads = 70% administrative overheads.
(N/D2005)

11. Estimate the electric arc welding cost for a cylindrical boiler drum 3m x 1.2m diameter which is to
be made from 15mm thick MS plates. Both the ends are closed by welding circular plates to the drum.
Cylindrical portion is welded along the longitudinal seam and welding is done both in inner and outer
sides. Assume the following data: 1. Rate of welding = 2m/hr on inner side and 2.5 m/hr on outer side:
2. Length of electrode require = 1.5 m/meter of welding:
3. Cost of electrode = Rs. 2.75/meter
4. Power consumption = 4KW/Hr per meter of weld
5. Power charges =45Paisa/HWhr
6. Labor charges = Rs. 9/hour
7. Overhead charges = 90% of prime cost
8. Discarded electrodes = 6%
9. Fatigue and setting up time = 5% of welding time.

12. Calculate the machining time required to produce one piece of component shown in figure starting
from 25mm bar. The following data is available for turning, cutting speed = 40m/min, feed =
0.4mm/rev, depth of cut = 2.5mm/pass, for thread cutting, cutting speed = 8m/min. (N/D 2013)

13. What is the feed per tooth of a 32 tooth milling cutter of 37.5cm diameter having a spindle of
75RPM and table speed is 28.75 cm per min. also find the time require to face mill a CI casting
1.2m long and 26 2/3 cm wide. Take allowance for start and end in to consideration.
14. Estimate the weight of the material required for manufacturing 220 pieces of shaft as shown

in fig.1. The shafts are made of mild steel which weighs 7.87 gm/cm 3 and costs Rs.4.25 per
kg. Also calculate the material cost for 220 such shafts.

15. Narrate the various objectives of cost estimation. What are all the elements of cost? Give
examples(Jun-12)
16. Calculate the net weight and gross weight for the manufacture of 500 levers shown in fig. the
material weight 7.8 gm/cm3 and total losses account for 25% of the net weight of the lever also
calculate (i) length of 3cm diameter required/component (ii) Cost of forging 500 pieces if the
material cost Rs. 8/Kg, Labor cost is Rs. 1.20/piece, and the over heads are 25% of material cost.
(M/J 2006)

17. A welded platform top is made by 20mm steel plates requiring 10 joints of 1 meter length each.
Welding is done on one side by arc welding process. Labor charges are Rs. 40/Hour. Electrode
require pre meter run in 2.5m and cost Rs. 20/mete. Power consumption is 6KWhr/Meter of the
weld and cost Rs. 8/KWhr. Time for welding 1 meter length 18min. Assume over heads as
Rs.40/Hr Calculate the welding expences. (N/D2007)
18. A M.S bar 120mm long & 40mm in diameter is turn to 38mm diameter and was again turn to a
diameter of 35mm over a length of 50mm as shown in figure. The bar was chamfer at both the
ends to give a chamfer of 45 x 4 mm after facing. Calculate the machining time. Assume cutting
speed of 50m/min and feed 0.3mm/rev. the depth of cut is not to exceed 3mm in any operation.
(N/D 2011)

19. A T-slot is to be cut in a CI slab as shown in figure. Estimate the machining time. Take cutting
speed 25m/min, feed is 0.25mm/rev. diameter of cutter for channel milling is 80mm. (N/D 2014)

20. Find the cost of welding for making 25 pieces of I-beams 1.2 m long with other dimensions of
flanges and web 16cm x 2cm and 12cm x 2cm respectively. The I-beam is made by welding two
channel section beams 1.2 metres long of dimensions shown in fig. The following data is available:
Cost of filler material = Rs.50/kg,cost of oxygen = Rs.15/m3,cost of acetylene =
Rs.60/m3,consumption of oxygen = 1.85 m3/hr,Consumption of acetylene = 1.85m3/hr, Diameter
of filler rod = 6mm,Density of filler material = 7.2 gm/cm3,Filler rod used per metre of weld =
9.75m,speed of welding = 0.95m/hr, Labour rate=Rs.40/hr,Overhead Charges =350% of labour
cost, Edge preparation time = 30% of time to weld. (Jun-13)

21. A 60 mm rod of aluminium to be machined on a lathe, the finished size is shown in figure. The
length of rod is 175 mm. Determine the total machining time and material cost, if material is
purchased at the rate of Rs. 12 per Kg. Assuming cutting speed 30 m/min and 0.2 mm/rev. Take
density of aluminium as 2.7 gm/cc. Depth of cut not to exceed 2.5 mm.( Apr/May 2015)