Course Code: 18ME27

Degree/Branch: B.E.-Mechanical Engineering Year/Semester: IV/VII

Course Code & Course Title: 18ME27 – Jigs, Fixtures and Tools in Body In White
MODULE - I
Part-A – Short Answer Questions (2 Marks)
1. What is a fit and how to define it? CO1 K1
2. List the different types of fits. CO1 K1
3. Draw the diagram for a clearance fit. CO1 K1
If a clearance fit is present between shaft and hole, what is the
4. tolerance on shaft or hole for a complete interchangeable CO1 K2
approach?
5. Draw the diagram for an interference fit. CO1 K2
6. Draw the diagram for a transition fit. CO1 K2
7. What are functional dimensions? CO1 K1
8. What is meant by deviation? CO1 K1
9. List the various types of deviation. CO1 K1

10. What is meant by allowance and provide the formulae for CO1 K1
calculating the same?
11. What is meant by tolerance and why is it important in CO1 K2
manufacturing?
12. List the various types of tolerance. CO1 K1
13. With an example brief on unilateral tolerance. CO1 K1
14. With an example brief on bilateral tolerance. CO1 K1
15. With an example brief on compound tolerance. CO1 K1
16. What is geometric tolerance? CO1 K1
Identify the type of tolerance for the below mentioned dimensions:
17. CO1 K2
a)
b)
18. Why tolerances are given to the parts? CO1 K1

19. What is meant by maximum metal limit (MML) and least metal limit CO1 K1
(LML)?
20. Write a short note on the concept of hole basis system. CO1 K1

21. Pictorially represent the hole basis system depicting the various CO1 K2
types of fits.
22. Write a short note on the concept of shaft basis system. CO1 K1

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 Course Code: 18ME27
23. Pictorially represent the shaft basis system depicting the various CO1 K2
types of fits.
24. Identify the importance of gauging and provide an example for a CO1 K2
gauge.
25. What is meant by interchangeability in manufacturing? CO1 K1
26. What is meant by selective assembly? CO1 K1
27. List the functions of the Indian Standard Institution (ISI). CO1 K1
28. Write about Geometric Dimensioning and Tolerancing (GD&T). CO1 K1
29. What is meant by angularity and draw the symbol for the same? CO1 K1
30. What is meant by parallelism and draw the symbol for the same? CO1 K1

31. What is meant by perpendicularity and draw the symbol for the CO1 K1
same?

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 Course Code: 18ME27

Degree/Branch: B.E.-Mechanical Engineering Year/Semester: IV/VII

Course Code & Course Title: 18ME27 – Jigs, Fixtures and Tools in Body In White
MODULE - I
1. With a neat diagram explain the following types of fits
i) Clearance fit (8) CO1 K2
ii) Interference fit (8) CO1 K2
2. Write short notes on the following
i) Allowance (8) CO1 K1
ii) Tolerance (8) CO1 K1
3. With an example explain the following tolerance types
i) Unilateral tolerance (8) CO1 K2
ii) Bilateral tolerance (8) CO1 K2
4. Explain the following concepts with a neat diagram
i) Hole basis system (8) CO1 K2
ii) Shaft basis system (8) CO1 K2
5. i) In a limit system, the following limits are specified for a (8) CO1 K3
hole and shaft assembly
Hole = mm, Shaft = mm
Determine the (a) tolerance (b) allowance
ii) Explain the concept of geometric tolerance (8) CO1 K2
6. i) The following limits are specified in a limit system to (8) CO1 K3
give a clearance fit between a hole and a shaft.
Hole = mm, Shaft = mm
Determine the following:
(a) Basic size
(b) Tolerance of shaft and hole
(c) Max & Min clearance
ii) With a neat diagram, explain maximum and minimum (8) CO1 K2
metal condition.
7. i) Explain with a neat diagram the purpose of GO and (8) CO1 K2
NO-GO gauges.
ii) Classify the various types of gauges (8) CO1 K2
8. i) Explain the following concepts of
a) Selective assembly (8) CO1 K2
b) Interchangeability (8) CO1 K2
9. i) Provide a detailed insight into the establishment of (10) CO1 K2
Indian Standard Institution (ISI).
ii) List the functions of ISI. (6) CO1 K1
10. i) Give a detailed insight into the concept of Geometric (10) CO1 K2
Design and Tolerancing (GD&T).
ii) Pictorially depict the differences in size tolerance (6) CO1 K2
drawing and geometric tolerance drawing and explain
the same.

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 Course Code: 18ME27

11. Describe all the GD&T terminologies that fall under the following categories
i) Orientation tolerance (8) CO1 K2
ii) Form tolerance (8) CO1 K2

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 Course Code: 18ME27

Degree/Branch: B.E.-Mechanical Engineering Year/Semester: IV/VII

Course Code & Course Title: 18ME27 – Jigs, Fixtures and Tools in Body In White
MODULE - II
Part-A – Short Answer Questions (2 Marks)
1. Differentiate between jig and fixture. CO2 K2
2. What is meant by 3-2-1 principle of location? CO2 K1
3. What do you mean by fool proofing? CO2 K1
4. Mention the different locating methods. CO2 K1
5. When is a diamond type locating pin used? CO3 K2
6. Sketch a quick acting clamp. CO2 K1
7. What is the purpose of a setting block in a fixture? CO2 K1
8. What are modular fixtures? CO2 K1
9. How do you define Degree of Freedom (DoF)? CO2 K1

10. How many DoF are considered for fixture designing and with a CO2 K2
simple diagram list the motions that are arrested.
11. What is meant by locating? CO2 K1
12. Mention the purpose of “V” locators. CO2 K1
13. Name the clamps depending on its actuation systems. CO2 K1

14. Identify the purpose of pads fixed with clamp faces. CO2 K1

15. Give the composition of materials used for JIG bushes. CO2 K1
16. What is the function of slip renewable bush? CO2 K1
17. With neat sketch, mention the functions of a JIG bush. CO2 K1
18. List the various types of drill jigs. CO2 K1
19. Name any four fixtures. CO2 K1
20. Why jig or fixture is used in mass production? CO2 K2
21. Name the types of locators used in jig design. CO2 K1
22. Why do we need a clamping device in manufacturing? CO2 K2
23. List the basic rules for a clamping device. CO2 K1

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 Course Code: 18ME27
24. Mention the types of actuations used in clamping devices. CO2 K1
25. Draw a simple plate jig with neatly labelled parts. CO2 K2
26. With a neatly labelled parts draw a template jig. CO2 K2

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 Course Code: 18ME27

27. Draw a channel jig with neatly labelled parts. CO2 K1

28. Provide the purpose of a diameter jig along with a neat sketch. CO2 K2
29. How does a leaf jig work? Provide the diagram for the same. CO2 K2
30. With neatly labelled parts draw a box jig. CO2 K1
31. For what applications, pot jigs are used? CO2 K1
32. Draw a pot jig with neatly labelled parts. CO2 K1
33. List the applications of post jig. CO2 K1
34. With neatly labelled parts draw a post jig. CO2 K1

35. List any four principles that are to be followed during construction of CO2 K1
a jig.
36. Name the basic components in a jig. CO2 K1

37. Name the common materials that are used in manufacturing a jig or CO2 K1
a fixture.
38. What is a welding fixture and what is its purpose? CO2 K1
39. Mention the two main aspects of location in jigs and fixture. CO2 K1
40. Which type of support pin or rest button is shown in below diagram? CO3 K3

41. Mention any 4 advantages of modular welding fixture. CO2 K1

42. Mention any 4 disadvantages of modular welding fixture. CO2 K1
43. Draw a fixture process layout. CO2 K1
44. Give examples for clamps with mechanical actuation system. CO2 K1

45. Write the formula for identifying the clamping force in a screw CO2 K1
clamp.
46. Draw a simple screw clamp. CO2 K1
47. List the limitation of screw clamp. CO2 K1
48. How does a hydraulic clamp work? CO2 K1
49. How does a pneumatic clamp work? CO2 K1
50. Draw a simple fluid power clamp. CO2 K1

51. Draw a welding fixture that is used for butt welding of pipes with U CO2 K2
bend.

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 Course Code: 18ME27

Degree/Branch: B.E.-Mechanical Engineering Year/Semester: IV/VII

Course Code & Course Title: 18ME27 – Jigs, Fixtures and Tools in Body In White
MODULE - II
1. Write short notes on
i Jigs and their types (8) CO2 K1
ii Fixtures their types (8) CO2 K1
2. With a neat sketch, describe the following
i Screw clamp (8) CO2 K1
ii Fluid power clamp (8) CO2 K1
3. Explain the following with a neat sketch
i Plate jig (8) CO2 K2
ii Template jig (8) CO2 K2
4. Explain the following with a neat sketch
i. Solid type jig (8) CO2 K2
ii. Leaf jig (8) CO2 K2
5. Elaborate on the following types of jig
i Channel jig (8) CO2 K2
ii Diameter jig (8) CO2 K2
6. With a neat sketch explain the following types of jig
i Box jig (8) CO2 K2
ii Pot jig (8) CO2 K2
7. Elaborate on the significance of the materials that are commonly used for
manufacturing a jig or a fixture
i High speed steel (8) CO2 K2
ii Cast iron (8) CO2 K2
8. With a neat diagram explain the six-point principle (or) 3-2-1 (16)
CO2 K2
locating principle.
9. Draw and explain a welding fixture that is designed to weld a (16)
CO3 K2
pipe with U bend
10. i Write short notes on modular welding fixture (8) CO2 K1
ii List the merits and demerits of modular welding fixture (8) CO2 K1
11. With a neat flow chart explain the various stages in a process (16)
CO2 CO2
flow chart.
12. Explain the construction and working of the following clamps:
i Bridge clamp (8) CO2 K2
ii Heel clamp (8) CO2 K2
13. Write short notes on the following clamps
i Latch clamp (8) CO2 K1
ii Hinged clamp (8) CO2 K1
14. Write short notes on the following clamps
i Edge clamp (8) CO2 K1
ii C- clamp (8) CO2 K1

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 Course Code: 18ME27

15. With a neat diagram explain the following clamps

i Cam operated clamp (8) CO2 K2
ii Wedge clamp (8) CO2 K2
16. Draw and explain the following clamps
i Quick acting nut (8) CO2 K2
ii Toggle clamp (8) CO2 K2
17. A toggle clamp shown in figure required to deliver a force of a 2000N in to the work-
piece in a fixture. Take the allowable shear stress in pin is 40 x 106 N/m2 and
coefficient of friction is 0.2.

Determine:
i Diameter of Pin (8) CO2 K3
ii Input force (8) CO2 K3
18. i With a neat diagram explain the construction and (8) CO2 K2
working of a screw clamp
ii Calculate the clamping force of the screw clamp for (8) CO2 K3
12mm hexagonal headed with 100 mm long spanner and
manual pull given to the spanner is 100 N. Helix angle is
30° and friction angle is 17° and pitch radius is 6.6 mm.

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 Course Code: 18ME27

Degree/Branch: B.E.-Mechanical Engineering Year/Semester: IV/VII

Course Code & Course Title: 18ME27 – Jigs, Fixtures and Tools in Body In White
MODULE - III
Part-A – Short Answer Questions (2 Marks)
1. What is meant by hemming in sheet metal? CO4 K1
2. Why is hemming performed on automobile components? CO4 K2
List the two different types of hemming usually performed on
3. CO4 K1
automobile components.
List the automobile components on which hemming operation is
4. CO4 K1
carried out.
5. What is the purpose of applying sealant in automobiles? CO4 K2
6. Give examples for automotive glass sealant. CO4 K1
7. Classify the different types of sheet metal operations. CO4 K1
8. With a diagram brief on channel bending. CO4 K2
9. Give a pictorial representation of U bending. CO4 K1
10. Give a pictorial representation of V bending. CO4 K1
11. What is blanking operation in sheet metal? CO4 K1
What do you understand by the term punching operation in sheet
12. CO4 K1
metal?
13. Differentiate between blanking and punching operation. CO4 K2
How can we differentiate punching operation from piercing
14. CO4 K2
operation in sheet metal?
15. What do you understand by the term conventional die hemming? CO4 K1
16. How does a roll hemming work and what is its significance? CO4 K2
What is Self-Piercing Riveting (SPR) and how does it aide in
17. CO4 K2
improving the joining of sheet metal?
18. List the stages in Self-Piercing Riveting (SPR). CO4 K1
19. Mention the merits of Self-Piercing Riveting (SPR). CO4 K1
Why dimple operation on sheet metal is carried out in automotive
20. CO4 K1
industry?
21. What is clinching process in sheet metal? CO4 K1
22. How do you define machine vision? CO4 K1
How does machine vision improve the product quality in automotive
23. CO4 K2
sector?
24. How does a machine vision system work? CO4 K1
25. Mention the role of machine vision in automotive industry. CO4 K1

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 Course Code: 18ME27

26. How does an arc welding machine work? CO4 K1

27. Draw the major components in an arc welding machine. CO4 K2
28. List the advantages of arc welding machine. CO4 K1
29. Mention the demerits of arc welding machine. CO4 K1
30. How do you define spot welding? CO2 K1
Draw a diagram to represent spot welding and name its major
31. CO2 K1
components.
32. Provide the applications of spot welding. CO2 K1
33. How does a resistance spot welding machine work? CO2 K1
Write the formula to calculate the heat energy generated in spot
34. CO2 K1
welding
35. Mention the merits of spot welding. CO2 K1
36. List the demerits of spot welding. CO2 K1
37. What do you mean by laser welding? CO4 K1
38. How is a laser welding performed on sheet metal? CO4 K2
39. List the materials that can be welded using laser welding technique. CO4 K1
40. List the types of welds that are carried out using laser welding. CO4 K1
41. Draw a diagram indicating the major components in a laser weld. CO4 K2
Mention the methods or techniques by which laser welding can be
42. CO4 K1
performed.
How is laser welding using heat conduction welding technique
43. CO4 K2
performed?
44. How is laser welding using key hole welding technique performed? CO4 K1
45. List the advantages of using laser welding. CO4 K1
46. List the disadvantages of using laser welding. CO4 K1
47. How are electrode materials classified in resistance spot welding? CO4 K1
What are Group A electrode materials in spot welding and what do
48. CO4 K2
they denote?
What are Group B electrode materials in spot welding and what do
49. CO4 K2
they denote?
50. Mention the types of electrode geometries. CO4 K1
Why is it important to select the electrode geometry depending on
51. CO4 K2
the application?
What are the factors that are to be considered in selecting an
52. CO4 K1
electrode for spot welding?
53. How is electrode cooling carried out? CO4 K2
54. Why is it necessary to cool an electrode? CO4 K2
55. Pictorially depict poor and good electrode cooling. CO4 K2
56. List the major defects in spot welding. CO2 K1
57. Identify the causes for any 4 defects in spot welds. CO4 K1
58. Mention the commonly conducted destructive testing of spot welds. CO4 K1
List the common nondestructive tests that are conducted on spot
59. CO4 K1
welds.
60. Why are nondestructive tests carried out on spot welds? CO4 K2
61. List any four commonly used automotive steels. CO4 K1
62. How are welding carried out on conventional uncoated steels CO4 K2
63. Give the techniques by which coated steels be welded. CO4 K1
64. How are zinc coated steels spot welded? CO4 K2

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 Course Code: 18ME27

Degree/Branch: B.E.-Mechanical Engineering Year/Semester: IV/VII

Course Code & Course Title: 18ME27 – Jigs, Fixtures and Tools in Body In White
MODULE - III
1. With a neat diagram write short notes on following sheet metal bending operations
i U - bending (8) CO4 K1
ii V – bending (8) CO4 K1
2. With a neat diagram write short notes on following sheet metal bending operations
i Offset bending (8) CO4 K1
Ii Edge bending (8) CO4 K1
3. With a neat sketch, describe the following sheet metal operations
i Shearing (8) CO4 K1
ii Bending (8) CO4 K1
4. With a neat sketch, describe the following sheet metal operations
i Blanking (8) CO4 K1
Ii Punching (8) CO4 K1
5. i Write short notes on hemming of sheet metal. (4) CO4 K1
ii Explain the following hemming techniques with a neat sketch
a) Conventional die hemming (6) CO4 K2
b) Roll hemming (6) CO4 K2
Explain the various stages in Self Piercing Riveting (SPR) process
6. (16) CO4 K2
with a neat sketch.
Explain the various stages in clinching operation along with a neat
7. (16) CO4 K2
sketch.
8. i Write short notes on machine vision (8) CO4 K1
Elaborate on the role played by machine vision in automobile
ii (8) CO4 K2
sector?
9. i With a neat diagram explain the arc welding process (8) CO4 K2
ii List the merits and demerits of arc welding process (8) CO4 K1
With a neat diagram, explain the resistance spot welding
10. i (8) CO2 K2
process
ii List the merits and demerits of spot-welding process (8) CO2 K1
11. i With a neat diagram, explain the laser welding process (8) CO4 K2
ii List the merits and demerits of laser welding process (8) CO4 K1
12. With a neat diagram explain the following laser welding types
i Heat conduction welding (8) CO4 K2
ii Key hole welding (8) CO4 K2
13. Elaborate on the following concepts in resistance spot welding
i. Electrode materials (8) CO4 K2
ii. Electrode geometry (8) CO4 K2
14. Discuss on the following concepts
i Electrode cooling (8) CO4 K2
ii Discontinuities & defects (8) CO4 K2
Elaborate on the following destructive testing techniques of spot
15.
welds
i Peel and chisel testing (8) CO4 K2
ii Tension shear and cross tension testing (8) CO4 K2
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 Course Code: 18ME27

16. i Explain about the impact testing on spot welds (10) CO4 K2
List the merits and demerits of destructive testing on spot
ii (6) CO4 K1
welds
17. i Explain the concept of non-destructive testing of spot welds. (6) CO4 K2
With a neat diagram explain the ultrasonic phased array testing
ii (10) CO4 K2
technique.
18. i Elaborate on the various automotive steel along with their
(6) CO4 K2
significance.
ii With a neat diagram explain the tensile strength (vs) elongation
(10) CO4 K2
graph for various automotive steels
19. Write short notes on
i Spot welding of conventional steels (6) CO4 K1
ii Spot welding of unconventional steels (10) CO4 K1
20. i Elaborate on spot welding of zinc coated steels (8) CO4 K2
ii Elaborate on spot welding of aluminium. (8) CO4 K2
21. i Two 1 mm thick steel sheets are to be spot welded at a current (8) K3
CO2
of 5000A. Assuming effective resistance to be 200micro-ohms
and current flow time of 0.2 second. Calculate the heat GATE - 2004
generated during the process.
ii Resistance spot welding is performed on two plates of 1.5mm (8) CO2 K3
thickness with 6mm diameter electrode, using 15000A current
for a time duration of 0.25sec. Assuming the interface GATE - 2001
resistance to be 0.0001Ω, Calculate the amount of heat that is
generated to form the weld.
22. Spot welding of two 1 mm thick sheets of steel (density=8000 kg/m3) (16) CO2 K3
is carried out successfully by passing a certain amount of current for
0.1 second through the electrodes. The resultant weld nugget formed
is 5 mm in diameter and 1.5 mm thick. If the latent heat of fusion of GATE - 2005
steel is 1400 kJ/kg and the effective resistance in the welding
operation in 200Ω, how much of current is passing through the
electrodes

Course Coordinator HoD/Mech

V.V. Arun Sankar Dr.C. Krishnaraj

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