KSR INSTITUTE FOR ENGINEERING AND TECHNOLOGY, TIRUCHENGODE- 637 215

MODEL EXAMINATION
Year/Semester : IV Year / VII Semester Max Marks : 100
Branch : MECHANICAL ENGINEERING Duration : 3 Hours
Subject Code & : ME6005 & PROCESS PLANNING AND COST Date & : 05.10.2018 & AN
Title ESTIMATION Session
Answer ALL the questions
PART-A (10 x 2=20)
1. Define process planning. K1
2. What are the factors to be considered during the selection of a process? K2
3. Classify the three basic functions of jigs and fixtures. K2
4. List the factors to be considered while selecting process parameters. K1
5. Distinguish between cost estimation and cost accounting. K4
6. What are the causes of depreciation? K2
7. What are the various material losses which can occur in a forging shop? K2
8. Give the formula for calculating the cost of power consumption in arc welding. K1
9. Define cutting speed. K1
10. Give the formula for estimation of machining time for drilling. K1
PART-B (5 x 13=65)
11. a. Explain in detail about the various types of process planning. (13) K2
(OR)
11. b.i) List out the factors that are common to both material and process selection. (6) K1
b.ii) List and explain the various factors considered for tooling selection. (7) K1
12. a. Explain in detail the process planning activities. (13) K2
(OR)
12. b.i) Explain the various principles of Jigs and Fixtures design. (7) K1
b.ii) What are the different types of inspection methods? Write briefly about them. (6) K2
13. a.i) Discuss various methods of costing in detail. (6) K2
a.ii) Explain the procedure followed for estimating the cost of an individual product. (7) K2
OR
b.i) An article can be made either by hand or in quantity by means of mass production methods. In the first case, the
time taken is 3 hrs and overheads are 30% of labour cost. In the later case the time taken is 160hrs per 1000
K3
articles, but overhead amount is 140% of labour cost. The material cost per piece is Rs.20 and rate of pay per
hour is Rs.8 in each case. Compare the factory costs in two cases. (6)
b.ii) An isometric view of a work piece is shown in figure. What will be
the weight of the material required to produce it. The density of
material is 2.681gm/cc. Find also the material cost if its rate is K3
Rs.13.60 per kg All dimensions are in mm. (7)

14. a. A welded platform top is made by 20 mm steel plates requiring 10 joints of 1 metre length each.
Welding is done on one side only by arc welding process. Labour charges are RS.15 per hour.
Electrode required per metre run in 2.5 m and costs Rs.6 per metre. Power consumption is 6 K3
Kwhr per metre of the weld and cost Rs. 3 per Kwhr. Time for welding 1 m length is 18
min. Assuming over heads as Rs.I0 per hour, calculate welding expenses.
OR
b. A cast iron hand wheel is required to be K3
manufactured is shown in fig. estimate the Wt. of
the hand wheel and selling price per dozen hand
 wheels, given the following data: (i) cost of pattern=Rs.50per 1000castings. (ii) Process scrap=25% (iii)
cost of molten metal at furnace=Rs.1.30per kg. (iv)Scrap return value=Rs.0.60 per kg. (v) Factory
overhead=Rs.8.0 per hour (vi) sales overhead=20% of manufacturing cost (vii) profit =20% of
manufacturing cost (viii) density of C.I =7.2gm/c.cm.
Process Time Rate/Hour Shop
overhead

Moulding and 15 minutes Rs.0.80 Rs.4.00/hr

pouring

Casting 5minutes Rs.0.60 Rs.1.20/hr

removal and
cutting

Fettling 6minutes Rs.0.60 Rs.1.20/hr

15. a. Estimate the machining time required to produce one piece of the component shown in Fig. starting from f 25
mm bar. The following data is available
For turinig
Cutting speed = 40m/min.
K3
Feed = 0.4mm/rev.
Depth of cut = 2.5mm/pass
For Threading
Cutting speed= 8m/min.
OR
b.i) A keyway has to be cut in a spindle whose dimensions are 46 cm length, 4 cm diameter and 1 cm width. The
cutter diameter is 13.25 cm. If cutter revolves at 120 rpm. What is the time required to cut a 1 cm deep key way K3
at a feed of 0.005cm/rev. of cutter. (8)
b.ii) Find the time required to drill 4 holes in a CI flange each of 2 cm depth, if the hole diameter is2 cm. Assume
K3
cutting speed as 21.9 m/min. and feed as 0.02 cm/rev. (5)
PART-C (1 x 15=15)
16. a. Analyze the component and Discuss the
production equipment and tool selection for
the component shown in fig. Under cut K4
diameter is 12mm.

(OR)
b. Analyze the component K4
shown in fig. and Prepare
the operation and route
sheet.

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