Model Test paper( AMM)
Note: Ques 1 is compulsory & Do 5 question from 7 question.
Ques 1(a) What is lean manufacturing?
Lean manufacturing, lean enterprise, or lean production, often simply, "lean", is a
production practice that considers the expenditure of resources for any goal other
than the creation of value for the end customer to be wasteful, and thus a target for
elimination. Working from the perspective of the customer who consumes a product
or service, "value" is defined as any action or process that a customer would be
willing to pay for.
Ques:1 (b) What is role of dielectric in EDM?
The functions of a dielectric fluid in Electric Discharge Machining process are as
follows:
• To serve as a spark conductor in the spark gap between the tool and work
material.
• To act as a coolant to quench the spark and to cool the tool and work piece.
• To carry away the condensed metal particles and to maintain the gap for
continuous and smooth operation
Ques: 1(c) What are the similarities between Agile & lean Manufacturing?
Lean and agile manufacturing are both ultimately focused on increasing business
sustainability in the high-cost manufacturing sector. Both are answers to challenges
faced by historical manufacturers, and both provide opportunities for smaller
players to compete with larger, entrenched competitors. Both concepts rely heavily
on statistical analysis, computerized information systems and open communication
between internal and external stakeholders. Because of this, both of these concepts
are tied to modern advances in production technology and are perfectly suited to the
tools and resources available to modern managers. Lean and agile design
considerations are both early stage planning decisions, influencing the way in which
organizations are structured from the accounting system all the down to the factory
floor.
Ques 1(d)How ultrasonic vibration are produced?
Ques 1(e)What is Group Technology?
Group Technology or GT is a manufacturing technique[1] in which the parts having
similarities in Geometry, manufacturing process and/or functions are assembled
together. GT is based on a general principle that many problems are similar and by
grouping similar problems, a single solution can be found to a set of problems, thus
saving time and effort.
The group of similar parts is known as part family and the group of machineries
used to process an individual part family is known as machine cell. It is not
necessary for each part of a part family to be processed by every machine of
corresponding machine cell. This type of manufacturing in which a part family is
produced by a machine cell is known as cellular manufacturing. The manufacturing
efficiencies are generally increased by employing GT because the required
operations may be confined to only a small cell and thus avoiding the need for
transportation of in-process
Ques1(f)what is role of abrasive grit in USM?
Ques:1(g) what is difference between batch & mass production?
The difference between the two is that batch productions is a form of production
that is applied to a large number of items all at once whilst mass production is the
same but made one at a time from mass produced parts
Ques:1(h) what is laser beam machining ?
Laser beam machining (LBM) is an unconventional machining process in which a
laser is directed towards the work piece for machining. Since the rays of a laser
beam are monochromatic and parallel it can be focused to a very small diameter
and can produce energy as high as 100 MW of energy for a square millimeter of
area. It is especially suited to making accurately placed holes. It can be used to
perform precision micro-machining on all microelectronic substrates such as
ceramic, silicon, diamond, and graphite. Examples of microelectronic micromachining include cutting, scribing & drilling all substrates
Ques:1(i)Explain Computer-integrated manufacturing (CIM)
Computer-integrated manufacturing (CIM) is the manufacturing approach of using
computers to control the entire production process.[1][2] This integration allows
individual processes to exchange information with each other and initiate actions.
Through the integration of computers, manufacturing can be faster and less errorprone, although the main advantage is the ability to create automated
manufacturing processes. Typically CIM relies on closed-loop control processes,
based on real-time input from sensors. It is also known as flexible design and
manufacturing
Ques: 1(j)List 3 application of USM?
Ques2 (a)What are process parameter in ECM?
Solution:
:
Ques2 (b) Explain Modelling of MRR in ECM?
Ques3: Explain principle of EDM with Neat diagram. What is selection process of
dielectric fluid in EDM?
Electric discharge machining (EDM) is a chipless metal removal process also known
as Spark Erosion Process. In an EDM metal removal operation, a dielectric fluid is
an important and essential working medium. Dielectric fluid is flushed through the
spark gap or supplied to the gap through a hole in the tool or from external jets. In
some operations the fluid is supplied through openings in the work piece if feasible.
The flow of this working medium is designed to take in specific directions to favour
the machining operations.
The essential requirements in the selection of the dielectric fluid for Electric
Discharge Machining (EDM) are as follows:
• It should have a stable and sufficient dielectric strength to act as insulation
between the tool and the work piece.
• It should have a low viscosity for smooth flow and high wettability.
• It should be chemically inert, so that the tool, work piece, container are not
attacked.
• It should be able to deionise immediately after the spark discharge.
• It should have a high flash point.
• It should not emit toxic vapours and should not have unpleasant odours.
• It should not alter its basic properties under operating conditions of temperature
variations, contamination by metal particles and products of decomposition.
• It should be economical for use.
Ques 4: What are the various approach of Lean Manufacturing? Explain them
briefly.
With a tools-based approach
With a muri or flow based approach (as
used in the TPS with suppliers).

Senior management to agree
and discuss their lean vision




Sort out as many of the
Management brainstorm to
visible quality problems as
identify project leader and
you can, as well as
set objectives
downtime and other
Communicate plan and
instability problems, and
vision to the workforce
get the internal scrap
Ask for volunteers to form
acknowledged and its
the lean implementation
management started.
team (5-7 works best, all



Make the flow of parts
from different departments)
through the system or
Appoint members of the
process as continuous as
lean manufacturing
possible using workcells
implementation team
and market locations
Train the Implementation
where necessary and
Team in the various lean
avoiding variations in the
tools - make a point of
operators work cycle
trying to visit other non
competing businesses that

Introduce standard work
and stabilize the work
have implemented lean


Select a Pilot Project to



through the system, look
place to start
at the production
Run the pilot for 2–3
scheduling and move
months - evaluate, review
toward daily orders with
and learn from your
kanban cards

Even out the production
Roll out pilot to other
flow by reducing batch
factory areas
sizes, increase delivery
Evaluate results, encourage
frequency internally and
feedback
if possible externally, level
Stabilize the positive results
internal demand
by teaching supervisors how

to train the new standards
you've developed with TWI

Start pulling work
implement – 5S is a good
mistakes

pace through the system
Improve exposed quality
issues using the tools

Remove some people (or
methodology (Training
increase quotas) and go
Within Industry)
through this work again
Once you are satisfied that
(the Oh No !! moment)
you have a habitual
program, consider
introducing the next lean
tool. Select the one that
gives you the biggest return
for your business.
Ques 5: What is EBM. Explain mechanism & principle of EBM with neat sketch.
Ques 6 Explain AJM principle with neat sketch.what are the application &disadvantage
of AJM?
Solution:
Abrasive jet machining (AJM), also known as abrasive micro-blasting, pencil blasting
and micro-abrasive blasting,[1] is an abrasive blasting machining process that uses
abrasives propelled by a high velocity gas to erode material from the workpiece.
Common uses include cutting heat-sensitive, brittle, thin, or hard materials. Specifically it
is used to cut intricate shapes or form specific edge shapes.
Material is removed by fine abrasive particles, usually about 0.001 in (0.025 mm) in
diameter, driven by a high velocity fluid stream; common gases are air or inert gases.
Pressures for the gas range from 25 to 130 psig (170–900 kPag) and speeds can be as
high as 300 m/s.
AJM machines are usually self-contained bench-top units. First it compresses the
gas and then mixes it with the abrasive in a mixing chamber. The gas passes
through a convergent-divergent nozzle before entering the mixing chamber, and
then exits through a convergent nozzle. The nozzle can be hand held or mounted in
a fixture for automatic operations.
Nozzles must be highly resistant to abrasion and are typically made of tungsten
carbide or synthetic sapphire. For average material removal, tungsten carbide
nozzles have a useful life of 12 to 30 hours, and sapphire nozzles last about
300 hours. The distance of the nozzle from the workpiece affects the size of the
machined area and the rate of material removal
The main advantages are its flexibility, low heat production, and ability to machine
hard and brittle materials. Its flexibility owes from its ability to use hoses to
transport the gas and abrasive to any part of the workpiece.[3][4]
One of the main disadvantages is its slow material removal rate; for this reason it is
usually used as a finishing process. Another disadvantage is that the process
produces a tapered cut