Q1.

1) Enumerate the limitations of conventional manufacturing processes particularly in the light of

present day manufacturing environment.

Conventional manufacturing processes face several limitations in today’s manufacturing environment.

Firstly, they often require expensive tooling and equipment setup, making them less flexible for small-
scale production or frequent design changes. Secondly, these processes may have limitations in
producing complex geometries or intricate designs. Thirdly, they can be time-consuming, leading to
longer production lead times. Additionally, conventional processes may generate significant material
waste and have limited ability to integrate advanced technologies like 3D printing or automation.
Overall, these limitations hinder agility, customization, and cost-efficiency in modern manufacturing.

Q2. 2) Distinguish between conventional and unconventional manufacturing processes.

Conventional manufacturing processes refer to traditional methods that have been widely used for a
long time, such as casting, machining, forging, and molding. These processes typically involve material
removal, shaping, or forming through physical means. On the other hand, unconventional
manufacturing processes are newer and innovative techniques that have emerged, like additive
manufacturing (3D printing), laser cutting, electrochemical machining, and nanotechnology-based
fabrication. Unconventional processes often involve layer-by-layer construction or material deposition,
enabling greater design freedom, customization, and the ability to manufacture complex geometries.

Q3. 3) Discuss under what circumstances you would not like to employ unconventional manufacturing
processes. Give examples to support your answer.

Unconventional manufacturing processes may not be suitable in certain circumstances. For example, if
high production volumes are required, traditional mass production methods like injection molding or
casting may be more efficient and cost-effective. Additionally, if the material properties or structural
integrity are critical, conventional processes that ensure precise control over material characteristics
may be preferred. Furthermore, if the upfront cost of acquiring specialized equipment for
unconventional processes outweighs the benefits for a specific application, conventional methods may
be a more practical choice.

Q4. 4) Critically analyse the need of new manufacturing process.

The need for new manufacturing processes arises from the evolving demands of modern industries.
New processes are essential to address the challenges posed by customization, rapid prototyping, and
shorter product lifecycles. They enable the production of complex geometries, lightweight structures,
and integration of advanced materials. Additionally, new processes like additive manufacturing offer
reduced material waste, increased design flexibility, and improved resource efficiency. Furthermore,
emerging technologies such as automation, robotics, and AI-driven systems necessitate the
development of new manufacturing processes to harness their full potential and enhance productivity.

Q5. 5) Classify new technique processes on the basis of energy being used, immediate basic
mechanism, source of immediate energy, energy transfer medium and processes.

New technique processes can be classified based on various factors:

1. Energy Usage: Differentiate between energy-intensive processes (e.g., metal casting) and
energy-efficient processes (e.g., additive manufacturing).
 2. Immediate Basic Mechanism: Categorize processes as additive (e.g., 3D printing), subtractive
(e.g., CNC machining), formative (e.g., forging), or transformative (e.g., heat treatment).
3. Source of Immediate Energy: Identify processes utilizing electrical energy (e.g., electric discharge
machining) or thermal energy (e.g., laser cutting).
4. Energy Transfer Medium: Distinguish between processes employing mechanical energy (e.g.,
milling) or chemical energy (e.g., chemical vapor deposition).
5. Processes: Categorize processes based on specific techniques like laser sintering, electron beam
melting, waterjet cutting, and ultrasonic welding.

Q6. 6) Compare the application of various new technique processes for aluminium alloy, steel, super
alloys, titanium, refractory materials and non-metals.

Various new technique processes have different applications for different materials:

1. Aluminium Alloy: Additive manufacturing (e.g., selective laser melting) and CNC machining are
commonly used.
2. Steel: Additive manufacturing (e.g., direct metal laser sintering), CNC machining, and traditional
forging are widely employed.
3. Super Alloys: Advanced techniques like electron beam melting and laser powder bed fusion are
utilized for intricate and high-temperature applications.
4. Titanium: Electron beam melting and laser-based techniques are commonly used due to the
material’s high melting point and reactivity.
5. Refractory Materials: Techniques like plasma spraying and chemical vapor deposition are
applied to deposit refractory coatings.
6. Non-Metals: Techniques such as 3D printing and laser cutting are employed for non-metal
materials like polymers, ceramics, and composites.

Q7. Why is proper flushing so important in EDM process? Explain the various components used in EDM
in brief.

Proper flushing is crucial in the EDM (Electrical Discharge Machining) process to ensure efficient material
removal and maintain stable machining conditions. Flushing serves several purposes: it removes debris
and eroded particles from the machining gap, cools the workpiece and electrode, replenishes dielectric
fluid, and prevents excessive sparking and electrode wear. Components in EDM include the power
supply (generating electrical pulses), electrode (tool), workpiece (material to be machined), dielectric
fluid (insulating and flushing medium), and the control system (managing parameters and movements).

Q8. What type of movement is imported to spindle in EDM process? What are the various materials of
which electrodes are made for EMI process and what are their advantages?

In the EDM process, the spindle undergoes rotational movement. This rotation helps to evenly distribute
the electrical discharge and prevent localized wear on the electrode.

Electrodes in the EDM process can be made from various materials such as copper, graphite, tungsten,
and brass. Copper electrodes offer good thermal conductivity, graphite electrodes provide high-speed
machining capability, tungsten electrodes offer high-temperature resistance, and brass electrodes are
suitable for fine finishing and intricate details. The choice of electrode material depends on the specific
requirements of the machining task.
Q9. What is the principle of working of Electro-discharge machining? What is overcutting in EDM
and how it is affected by amperage and frequency?

The principle of Electro-Discharge Machining (EDM) involves using electrical discharges to remove
material from a workpiece. A voltage difference is applied between an electrode (tool) and the
workpiece, creating a series of rapid electrical discharges. These discharges generate intense heat,
melting and vaporizing the material, which is then flushed away by a dielectric fluid.

Overcutting in EDM refers to the undesired removal of additional material beyond the intended shape
or dimensions. It is affected by the amperage and frequency settings. Higher amperage and lower
frequency settings tend to cause more overcutting, while lower amperage and higher frequency settings
result in less overcutting. Proper adjustment of these parameters is important to control overcutting and
achieve desired machining accuracy.

Q10. On what types of works the process of EDM is best suited? Explain the basic scheme of EDM
process. What are the critical parameters and limitations of the process of machining in such a machine?

EDM is best suited for works involving complex shapes, intricate details, and hard materials. It is
commonly used in tool and die making, mold making, aerospace, and medical industries.

The basic scheme of the EDM process involves a power supply generating electrical pulses, a dielectric
fluid acting as an insulating and flushing medium, and a tool electrode and workpiece submerged in the
dielectric fluid. Electrical discharges occur between the electrode and workpiece, causing material
removal.

Critical parameters in EDM include discharge current, pulse duration, gap distance, and flushing rate.
Limitations include slow machining speed, high tool wear, limited material thickness, and the need for
post-m surface finishing.

Q11. Explain the mechanism of EDM. What is wire cut EDM? Indicate its special applications.

The mechanism of EDM (Electrical Discharge Machining) involves the creation of electrical discharges
between a tool electrode and a conductive workpiece. When a voltage is applied, a spark discharge
occurs, melting and vaporizing small portions of the workpiece material. The molten material is then
flushed away by a dielectric fluid. This process is repeated rapidly, gradually eroding the workpiece and
achieving the desired shape.

Wire cut EDM, also known as Wire Electrical Discharge Machining (WEDM) or wire EDM, uses a thin wire
electrode to cut through the workpiece. The wire is guided along a programmed path, controlled by a
CNC system. Wire cut EDM is especially suitable for precision cutting of complex shapes, such as in the
production of dies, molds, and intricate parts with tight tolerances. It is commonly used in industries like
automotive, aerospace, and electronics.

Q12. Explain the advantages and limitations of EBM and EBW?

Electron Beam Melting (EBM) and Electron Beam Welding (EBW) have their respective advantages and
limitations. EBM offers advantages such as the ability to produce complex, fully dense parts with
excellent material properties and reduced material waste. However, it has limitations in terms of slower
build times and limited build sizes.
EBW provides advantages like high precision, deep penetration, and the ability to weld thick materials.
However, it is limited by the need for vacuum environments, limited joint access, and sensitivity to
variations in workpiece surface conditions.

Q13. ‘Material Removal Rate in Electron Beam Machining is quite low.” Explain why. What is its
substitute.

The material removal rate in Electron Beam Machining (EBM) is relatively low due to the nature of the
process. EBM utilizes a high-energy electron beam to melt and vaporize the material, which results in
gradual material removal. The beam size is typically small, leading to a slower material removal rate
compared to other machining processes like milling or turning.

A substitute for EBM with higher material removal rates is Electron Beam Machining (EBM). EDM uses
electrical discharges to erode the material, allowing for faster material removal rates. EDM is especially
suitable for machining hard and complex shapes, offering higher productivity compared to EBM.

Q14. Explain LBM with suitable diagram

LBM stands for Laser Beam Machining, which is a non-contact machining process that utilizes a high-
power laser beam to remove material from the workpiece. The laser beam is focused on the workpiece
surface, resulting in localized heating and vaporization of the material. The vaporized material is
expelled by the assist gas, leaving behind a machined cavity. Here is a simplified diagram illustrating the
basic concept of LBM:

[Diagram: A laser beam focused on a workpiece, causing material removal through vaporization.]

Q15. Explain the critical parameters and limitations of LBM.

The critical parameters in Laser Beam Machining (LBM) include laser power, beam diameter, scanning
speed, and assist gas flow rate. Laser power determines the amount of energy delivered, beam diameter
affects the spot size and heat distribution, scanning speed influences the material removal rate, and
assist gas flow rate aids in debris removal.

Limitations of LBM include limited material thickness due to excessive heat input, potential thermal
damage to the workpiece, and difficulty in machining highly reflective or transparent materials.
Additionally, the process may require skilled operators and can be cost-prohibitive for large-scale
production.

Q16. Mention the advantages and disadvantages of LBM. What are its areas of application?

Advantages of Laser Beam Machining (LBM) include high precision, non-contact process, minimal tool
wear, and the ability to machine complex and delicate shapes. LBM also allows for narrow kerf width
and minimal heat-affected zone. However, it has limitations such as limited material thickness, potential
thermal damage, and high equipment and operating costs.

LBM finds applications in industries like aerospace, automotive, electronics, medical devices, and
jewelry. It is used for cutting, drilling, welding, engraving, surface texturing, and micro-machining tasks.

Q17 What are the various precautions that should be taken while performing explosive welding?

Several precautions should be taken while performing explosive welding:

 1. Adequate safety measures, including protective gear, should be worn by personnel involved in
the process.
2. The work area should be clear of any flammable materials or hazards.
3. The welding setup should be securely fixed to prevent displacement during the explosion.
4. A sufficient distance between the explosive charge and the workpiece should be maintained for
safety.
5. Proper handling, storage, and disposal of explosive materials should be strictly followed to
prevent accidents.

Q18. What are the advantages and disadvantages of parallel plate type arrangement over inclined plate
arrangement?

The parallel plate type arrangement and inclined plate arrangement are both methods used in plate-
type electrostatic precipitators.

Advantages of the parallel plate arrangement include simplicity, ease of cleaning, and uniform gas
distribution. It is suitable for high-velocity gas streams and can handle a wide range of particulate sizes.

The Inclined plate arrangement offers advantages such as increased collection efficiency and reduced re-
entrainment. It is effective for handling smaller particulate sizes and sticky or moist particles.

Disadvantages of the parallel plate arrangement include lower collection efficiency for fine particles,
while the inclined plate arrangement may require more complex design and maintenance due to the
inclination angle.

Q19. Explain the requirements to be met for the metallurgical bonding between two pieces of metals?
How does explosive welding process meet these?

Metallurgical bonding between two pieces of metals requires three main requirements: sufficient
interfacial contact, high temperature, and pressure. The explosive welding process meets these
requirements by utilizing a controlled detonation to generate a high-pressure shockwave that brings the
metal surfaces into intimate contact. The resulting collision creates a localized area of high temperature
and pressure, facilitating atomic diffusion and metallurgical bonding. The explosive welding process
ensures strong and reliable bonding between the metals due to the intense energy and pressure
involved.

Q20. Explain how would you employ explosive welding process for obtaining multilayered weld?

To obtain a multilayered weld using the explosive welding process, a sequential layering technique can
be employed. The process involves placing alternating layers of the desired metals on top of each other.
An explosive charge is then detonated, creating a high-pressure shockwave that brings the layers into
contact and bonds them together. By repeating this layering and explosive bonding process multiple
times, a multilayered weld can be achieved, with each layer consisting of different metals or alloys,
providing specific properties or functionalities to the final structure.

Q21. Explain the type of bond formed between the parent material and material being welded? How is
the process used for cladding?
The type of bond formed between the parent material and the material being welded in explosive
welding is a metallurgical bond. In this bond, atomic diffusion occurs at the interface of the two
materials due to the high-pressure and high-temperature conditions generated by the explosive
detonation. The process is used for cladding by placing a layer of the cladding material onto the parent
material, and then subjecting them to the explosive welding process, resulting in a strong and durable
metallurgical bond between the two layers.

Q22. Name two distinctive advantages and limitations of explosive forming.

Two distinctive advantages of explosive forming are its ability to shape complex and intricate geometries
that are difficult to achieve using traditional forming methods and its suitability for forming large
components. On the other hand, limitations of explosive forming include the potential for residual
stresses and deformation in the formed part, as well as the need for specialized equipment, safety
precautions, and expertise in explosive handling and setup. Additionally, the process may require
additional machining or finishing steps to achieve the desired final specifications.

Q23 What are the various types of electro-hydraulic forming?

There are several types of electro-hydraulic forming techniques. One type is electro-hydraulic sheet
metal forming, which uses high-voltage electric discharge to generate a shockwave that deforms the
metal sheet. Another type is electro-hydraulic bulging, where a high-voltage discharge is applied to a
liquid medium to create a pressure wave that forms a desired shape in a workpiece. Additionally,
electro-hydraulic tube forming involves applying high-voltage discharge to a conductive liquid inside a
tube to cause radial expansion or deformation of the tube.

Q24. Enlist various explosives that can be used in explosive compaction.

Various explosives can be used in explosive compaction processes. Some commonly used explosives
include TNT (Trinitrotoluene), RDX (Cyclotrimethylenetrinitramine), HMX
(Cyclotetramethylenetetranitramine), PETN (Pentaerythritol tetranitrate), ANFO (Ammonium Nitrate
Fuel Oil), and Composition B (a mixture of TNT and RDX). The selection of the explosive depends on
factors such as desired energy release, sensitivity, stability, and safety requirements for the specific
compaction application. It is crucial to follow safety protocols and guidelines when handling and using
explosives.

Q25. What is the difference between explosive forming and explosive compaction?

The main difference between explosive forming and explosive compaction lies in their objectives and
outcomes. Explosive forming involves using controlled explosive charges to shape or deform metal
sheets, tubes, or components into desired geometries. It aims to achieve specific shapes or contours. On
the other hand, explosive compaction focuses on compacting or consolidating powders or particulate
materials using explosive forces. It is used to enhance material density, eliminate voids, or create near-
net shape components through the application of explosive energy.

Q26. Explain the importance of topographic simulation in semiconductor manufacturing.

Topographic simulation plays a crucial role in semiconductor manufacturing by enabling the accurate
prediction and analysis of surface topography during various fabrication processes. It helps to optimize
process parameters, minimize defects, and ensure the desired quality of semiconductor devices. By
simulating the deposition, etching, and planarization steps, it assists in predicting and controlling
features such as step heights, surface roughness, and uniformity. This information aids in process
optimization, yield improvement, and overall performance enhancement in semiconductor
manufacturing.