K.S.R.COLLEGE OF ENGINEERING YEAR QUESTION BANK.pdf · Statistical Gauss, Pareto, Shewhart, Fisher...
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K.S.R.COLLEGE OF ENGINEERING (An Autonomous Institution) (Approved by AICTE, Affiliated to Anna University, Accredited by NAAC with A Grade) FOR IV – YEAR, VIII - SEMESTER B.E., PROGRAMME (2018-2019) DEPARTMENT OF MECHANICAL ENGINEERING
Transcript of K.S.R.COLLEGE OF ENGINEERING YEAR QUESTION BANK.pdf · Statistical Gauss, Pareto, Shewhart, Fisher...
K.S.R.COLLEGE OF ENGINEERING
(An Autonomous Institution) (Approved by AICTE, Affiliated to Anna University, Accredited by NAAC with A
Grade)
FOR
IV – YEAR, VIII - SEMESTER
B.E., PROGRAMME
(2018-2019)
DEPARTMENT OF MECHANICAL
ENGINEERING
UNIT – I
PART-A
TWO MARKS Q&A
1. What is TQM?
TQM is the art of managing the whole to achieve excellence.
Total - Made up of the whole
Quality - Degree of excellence a product or service provides
Management - Act, Art, Manner of handling, controlling and directing etc.
2. Define TQM.
“TQM is the management approach of an organisation, centered on quality, based on the
participation of all its members and aiming at long-term success through customer satisfaction,
and benefits to all members of the organization and to society. “
International Organization for Standardization (ISO)
3. Define quality. (AU Nov/Dec 2010, 2011 & May/June 2012)
Definition of quality, according to ISO 9000:2000.
“Quality is the Degree to which a set of inherent characteristics fulfills requirements”.
Performance P
Quality = ---------------- (or) Q = ----
Expectations E
Degree Quality can be used with adjectives poor, good Excellent.
Inherent Existing in something.
Characteristics Can be Quantitative or Qualitative.
Requirement A need or expectation that is generally implied by
Organization, its customers and other interested parties.
4. What are the objectives of Total Quality Management?
100% customer satisfaction, Producing the products as per the needs of
customers and obtain the full satisfaction from customers.
Zero defects production of products or deliver the services with no defects.
These are the main objectives of TQM.
5. List the elements of TQM.
Constancy of purpose
/Long term
commitment
Training Focus on
Process
Total employee
involvement /
Teamwork
Quantitative
methods
Continuous
process
improvement
Leadership
Customer focus Supplier
Partnership
TQM
6. Explain the Juran’s fitness of quality.
Quality of design – Through market research product and concept.
Quality by conformance – Through management, Manpower and Technology.
Availability –Through reliability, Maintain ability and logistic support.
Full service – Through promptness, competence and Integrity.
7. Explain Juran’s Quality planning Roadmap.
Identify your customers
Determine their needs
Translate them into your language
Develop a product that can respond to the needs
Develop processes, which are able to produce those product features
Transfer that the process can produce the product
Transfer the resulting plans to the operating forces.
8. What are the Crosby’s four absolutes of Quality?
Quality is conformance to requirements nothing more or less and certainly not
goodness or elegance
Quality has to be achieved by prevention and not by appraisal
The performance standard must be zero defects and not something close to it.
The measurement of quality is the price of non-conformance is, how much the
defects in design, manufacture, installation and service cost of the company.
9. Define Quality Statement. (AU Nov/Dec 2008)
Quality statements are defined as the one which declare the cove values and concepts,
vision and mission and quality polities of the organization. Once developed they are reviewed
and updated sometimes. These statement form part of strategic planning. Quality statements are
established by the quality council to provide overall direction for achieving the total quality
culture.
Three elements of quality statements are :
1) Vision statement
2) Mission statement and
3) Quality policy statement.
10. Define Vision Statement. (AU Nov/Dec 2007)
Vision statement is defined as the one which contains the brief declaration on the
expectations of an organization. It is the ideal state which an organization strives continually to
achieve.
Visions are eternal, inspirational and shared fully within the organization.
Ex: Disney theme Park’s Vision
“Happiest Place on Earth”
11. Define Mission Statement.
Mission statement describes the activities of the organization. It provides a clear
statement of the aim for the employees, projected customers and suppliers as well.
Ex: To meet customers transport and distribution needs and by being the best at moving
their goods on time safely and damage free => Railway Company.
12. What is the contribution of Gurus for TQM? (OR) List the areas of TQM that are
concentrated by quality gurus.
Areas of TQM Gurus
Statistical Gauss, Pareto, Shewhart, Fisher
Management Juran, Crosby, Feigenbaum
Execution Deming, Taguchi
13. List out the basic concepts of total quality management. (AU Nov/Dec 2006)
The basic concepts required for TQM are
Committed and involved management to provide long term and top-to-bottom
organizational support.
Focus on consumer.
Effective involvement and utilization of entire work force.
Continuous improvement of the business and production process. Treating
suppliers as partners.
Establish performance measures for the processes.
Customer is the king
Right first time
Benchmarking
Synergy in team work
Involvement
Value addition
Continuous improvement
Education and Training
Prevention is better than detection
Management commitment
14. List the steps given by Juran for Quality improvement. (AU Apr/May ’05)
Build awareness of opportunities to improve
Set goals for improvement
Organize to reach goals
Provide Training
Carryout projects to solve problems
Report Progress
Give Recognition
Communicate results
Keep score
Maintain momentum by making annual improvement part of the regular systems
and processes of the company.
These are the ten steps given by Juran for quality improvement.
15. List the TQM models that are used by the organization
Deming application price
Malcolm Balridge criteria for performance excellence
European foundation for quality management
ISO quality management standards.
16. List the basic principles of TQM. (Or) State the seven underlying principles of TQM.
(AU Exam, April/May 2005, Nov/Dec 2009)
The principles of TQM are:
Customer focus
Leadership
Involvement of people
Process approach
System approach to management
Continual improvement
Factual approach to decision making
17. State the barriers to TQM implementation in organisation. (AU Nov/Dec 2010,
May/June 2012)
The following are the barriers to TQM implementation;
Fear of the unknown
Perceived loss of control
Personal uncertainty
An unwillingness to take ownership and be committed to change
Dis interest at site level
Lack of understanding of what TQM was particularly on sites.
Fear of job losses
In adequate training
Plan not clearly defined and Resistance to data collection
18. Define quality as per Crosby. (AU April/May 2008)
Quality has been defined in various ways and the definition given by Crosby is as
follows:
“Quality is conformance to requirements”.
19. Name any two popular awards for quality.
(i) Malcome Baldrige National Quantity Award (MBNQA)
(ii) Deming Prize
20. What are the dimensions of quality? (AU Nov/Dec 2007)
There are nine dimensions of quality. They are:
Performance
Features
Conformance
Reliability
Durability
Service
Response
Aesthetics
Reputation
21. What are the basic concepts required for TQM?
Top management commitment
Effective involvement & utilization of the entire work force
Continuous improvement
22. Define Quality as per Ed. Deming. (AU Nov/Dec 2008)
Quality is predictable degree of uniformity and dependability, at low cost and suited to
the market.
23. Write the equation that would quantify quality. (AU Nov/Dec 2007)
Quality can be quantified as follows:
Performance P
Quality = ---------------- (or) Q = ----
Expectations E
24. Mention the benefits of quality to a firm? (AU Nov/Dec 2010)
Quality is an expression of the products or services by means of performance, reliability,
safety, durability and so on, and if the firms are providing their products or services with quality
they can earn goodwill among customers that will lead to increase in purchase of their products
or services.
25. List out various responsibilities of senior management. (AU Nov/Dec 2010)
The senior management has some responsibilities and they are:-
To study and investigate the TQM concepts and issues
To set clear quality policies and provide changing tasks
To establish ‘priority of quality’ and ‘customers satisfaction’ as the basic policy and
determine long term goals
To bring a cultural change required for the total quality management effort
To establish the TQM vision for the future and communicate to all involved
To became coaches and leaders for encouraging and supporting the managers during the
transition phase of the transformation change
To teach employees to realize that the company’s interest and their interest are geared into
one another
To attend TQM training programs.
To create coordination and harmony among and with in departments
To monitor whether quality improvement programs are conducted as planned
To create a basic of trust, respect and open communication which ensures individual
participation and continuous improvement
PART – B
1. Define dimensions of quality and explain it in detail.
7. Explain the principles of TQM in detail. (or) Explain any five principles of TQM.
8. Explain in detail Deming Philosophy (OR) Explain the “Codes of Ethics for Quality”.
(or) Enumerate Deming’s fourteen points of management.
9. Explain in detail the implementation of TQM
10. List out the obstacles or barriers to the implementation of TQM.
11. Explain the fourteen points of Crosby.
UNIVERSITY QUESTIONS
1. Indicate the dimensions of quality with examples. (Nov/Dec2007&2010)
2. What are the duties of quality council? Explain in detail. (Nov/Dec 2006, Nov/Dec 2007)
3. Enumerate Deming’s 14 points of management. (Nov/Dec 2007, May/June 2006)
4. Explain principles of TQM. (Nov/Dec07,08&10, May/June 09)
5. Enumerate the barriers to TQM implementation. (Nov/Dec07&08,May/June 09)
6. Explain the steps of strategic planning. (Nov/Dec 07&08, Nov/Dec 2006)
7. What should a leader know and understand in order to be effective. (Nov/Dec 2006)
8. How are the quality costs categorized? Explain in detail. (Nov/Dec 2006)
9. Explain the fourteen steps of Deming’s philosophy for improving quality, productivity
and competitiveness. (May/June 09 & April/ May 08)
10. Discuss about the analysis techniques for the quality cost. (Nov/Dec08)
11) Explain about quality council and quality planning. (April/ May 2008)
11. Explain the contribution of Juran to the quality movement. (April/ May 2008)
12. Discuss about the implementation steps of TQM and mention the importance of the
management commitment. (April/ May 2008)
13. Explain the process of establishing cost of Quality. (Nov/Dec09)
14. State & explain the principles of TQM. (Nov/Dec09)
15. Write short notes on quality statements. (Nov/Dec 2010)
UNIT 2
PART-A
TWO MARKS Q&A
1. Define leader.
A Leader is one who instills purposes, strengthens and inspires followers to accomplish
shared goals. A great leader inspires confidence in other people and moves them to action.
2. List the essentials needed for a leader to be an effective leader (or)
What is the basic concept of leadership? (AU Nov/Dec 06)
People need security as well as independence at the same time.
Employees are very sensitive to external rewards and punishments and yet
strongly motivated.
People prefer hearing a kind word of praise from superior. The leader should
‘Catch them doing something right, so that he/she can pat them on the back’.
People can process only a few facts at a time. Hence the leader should start with
simple things.
People distrust their leaders, who are merely rhetoric if the words are inconsistent
with leader’s actions.
3. Define Quality Statement. (AU Nov/Dec 2008)
Quality statements are defined as the one which declare the cove values and concepts,
vision and mission and quality polities of the organization. Once developed they are
reviewed and updated sometimes. These statement form part of strategic planning. Quality
statements are established by the quality council to provide overall direction for achieving
the total quality culture.
4. Define Quality Policy Statement.
Quality policy statement provides a direction to employees in the organization as how
they should provide products and services to customers.
It is drafted by Chief Executive upon the feedback from the employees and finally gets
approved by the quality council.
5. List the characteristics of policy statement.
Quality first, always
Fulfills the needs of the customers
Excel in competition
Quality improvement continually
6. List the steps to evaluate customer satisfaction.
Study the buying procedures of each customer organization and map them with
respect to individuals.
Determine the factors of buyer-seller interactions
Analyze the trends of above and formulate the indices, to represent of all relevant
features such as repeat orders, switching suppliers, and number of customers lost as
well as gained.
7. List the factors that are determining the customer satisfaction.
Quality of supply
Product installation/commissioning
Product performance, ease of operation and control
After sales service
Reliability
Maintainability
Serviceability.
8. Define-Employee involvement (April/May’05)
Employee involvement is an approach to improve quality and productivity. It is a mean
to better meet the organization’s goals for quality and productivity at all the levels of an
organization. Employee involvement is possible by
Educating the employees
Providing training to the employees
Empowerment
Participating in groups.
9. Define team and teamwork.
A team is defined as a group of people working together to achieve common objectives
or goals. Team work is the cumulative actions of the team during which each member of the
team subordinates his individual interests and opinions to fulfil the objectives or goals of the
group.
10. Explain the steps of training.
First step in the training process is to make everyone aware of what the training is
all about.
To get acceptance
To adopt the program
To adopt what has been agreed upon
11. List the essentials of an effective recognition and reward system.
Serves as a continual remainder that the organization regards quality and productivity as
important.
Offers the organization a visible technique to thank high achievers for outstanding
performance
Provides employees a specific goal to work toward. It motivates them to improve the
process.
Boosts morale in the work environment by creating healthy sense of competition among
12. List out the objectives that can be achieved by the performance measures.
Establish base line measures and reveal trends.
Determine which processes need to be improved.
Indicate process gains and losses
Compare goals with actual performance
Provide information for individual and tem evaluation.
Provide information to make informed decisions
Determine the overall performance of the organization.
13. Explain the way by which strategic measurement system is created?
The quality council has the overall responsibility for the performance measures. It
ensures that all the measures are integrated into a total system of measures. To develop the
system the quality council will obtain appropriate information from all of the state holders. They
will utilize the core values, goals mission and vision statements as well as the objectives and
criteria. Based on all these information the strategic measurement system is created.
14. List the techniques available for presenting the performance measures.
i. Time series Graph
ii. Control chart
iii. Capability index
iv. Taguchi’s loss function
v. Cost of poor Quality
vi. Malcolm Balridge National Quality Award
15. What are the various tools used for collecting customer complaints?
The various tools used for collecting customer complaints are:
1. Comment Card
2. Customer Questionnaire
3. Focus Groups
4. Toll free Telephone Numbers
5. Customer Visits
6. Report Card
7. Employee Feedback
8. Mass Customization
16. What is meant by customer retention? (AU Nov/Dec 09 & 10)
Customer retention is the process of retaining the existing customers. Customer retention
can be improved by obtaining customer feedback and by measuring customer satisfaction.
Customer retention represents the activities that produce the necessary customer satisfaction that
creates customer loyalty.
17. Define motivation. What are the basic needs of Maslow? or Write short notes on
Maslow’s hierarchy of needs. (AU Nov/Dec 2006)
Abraham Maslow believes that good qualities are inherent in people at least at birth;
although later on they are gradually lost. He believes that give basic human needs motivate the
employees. Motivation is a process of stimulating people to accomplish desired goals.
According the Maslow, human motivation is a hierarchy of five needs. They are
1) Physical or physiological needs
2) Safety or security needs
3) Social needs
4) Esteem needs
5) Self-actualization needs
18. What are the conditions to create the empowered environment? (AU Nov/Dec 2006)
Empowerment involves giving people the means, ability and authority to do something
they have not done before.
The conditions required are:
1. Everyone must understand the need for change
2. The system needs to change to the new paradigm.
3. The organization must provide information, education and skill to its employees.
19. Difference between recognition and reward. (AU Nov/Dec 2007)
Recognition Reward
1. Recognition is a process whereby
management shows acknowledgement
of an employee’s outstanding
performance.
2. Recognition improves employees’
morale, create satisfied workplace &
stimulate creative efforts.
1. Reward is a tangible one such as
increased salaries, commissions, cash
bonus etc., to promote desirable
behaviour.
2. Two types of rewards: intrinsic
rewards and extrinsic rewards.
20. What is the use of performance appraisal? (AU May/June 2006)
Performance appraisal is a systematic and objective assessment or evaluation of
performance and contribution of an individual. It provides useful feedback to the employee in
taking corrective measures to improve performance further.
21. Expand 5S (or) Name the 5 S. (AU April/May 2005, Nov/Dec 2007)
The 5S practice is a house keeping technique used to establish and maintain a productive
and quality environment in an organization. 5S stands for
1. SEIRI - Tidiness
2. SEITON - Orderliness
3. SEISO - Cleanliness
4. SEIKETSU - Standardization
5. SHITSUKE - Discipline
22. What is Kaizen? (AU Nov/Dec 2010)
Kaizen is a Japanese word which means continuous improvement or improvement over
improvement. It is the process of continuous improvements in small increments that make the
process more efficient, effective, controllable and adequate.
23. Differentiate between sole sourcing and single sourcing.
Sole sourcing is the use of only one supplier for the organization. The organization does
not have any choice because of the factors like patents, raw materials location, technical
specifications, only one organization producing the item.
Single sourcing is the use of one supplier for an item when several sources are available.
It leads to long term patterning relationship.
24. What does the term relationship development refer?
Relationship development refers to maintaining and improving the growth of the
customer – Supplier relationship. The partnering relationship between the customer and the
supplier can be developed through:
1. Inspection
2. Training
3. Team approach
4. Recognition
25. How teams can be classified?
A team can be defined as a group of people working together to achieve common goals.
Teams can be classified into four groups.
They are :-
1. Process improvement team
2. Cross – functional team
3. National work team
4. Self directed team
26. Why is customer complaint necessary? (AU Nov/Dec 2010)
Customer opinions and complaints regarding the products are obtained by the feedback
method. Customer feedback or customer complaint is required:
To discover customer dissatisfaction.
To identify customer’s needs.
To discover relative priorities of quality,
To compare performance with the competition and
To determine opportunities for improvement.
27. What is service quality or customer service. (AU April/May 2008)
Customer service is the set of activities an organization used to satisfy the customers
and their needs. The services can be provided at:
i) Before the sale of the product
ii) During the sale of the product
iii) After the sale of the product
28. What are the benefits of empowerment? (AU Nov/Dec 2007)
The following are the benefits of empowerment;
1. Employees feel responsible for their own work
2. Employees are challenged and encouraged.
3. Employees monitor and improve their work continuously.
4. Employees find new goals and change challenges.
29. What are the benefits of 5 S? (AU May/June 2006)
The benefits in implementing 5s are
1. Work place becomes clean and better organized. It becomes proud place to work.
2.Results in good company image and generates more business.
3.Better quality awareness
4.More usable floor space.
5.High employee involvement
30. What is supplier selection? (AU Nov/Dec 2010 & Nov/Dec 2008)
Suppliers are selected based on their performance in terms of cost, quality, and delivery
reliability. In addition, supplier criteria includes factors such as management compatibility, goal
congruence, and strategic direction of the supplier firm. There are four stages in supplier
selection.
1) Survey Stage
2) Enquiry stage
3) Negotiation and selection Stage.
4) Experience Stage.
PART-B
1. Explain in detail customer perception of Quality (or) Explain the factors influencing
purchases. (AU May/June 2006 &Nov/Dec 2010)
2. Explain in detail customer complaints (or) Explain the ways by which the feedback is obtained
from the customers.
3. Explain in detail service quality (or) Explain in detail the element of customer service (or)
Explain service quality with its expectations and characteristics. (AU May/June 2006 & Nov/Dec
2011)
4. Explain in detail (i) Customer satisfaction Model (or) Kano model (ii) Customer Retention
model. (APR/MAR ’05)
5. Explain in detail motivation and theories of motivation.
6. Explain in detail the characteristics of successful teams.
7. Explain the stages of team development
8. Explain the common team problems and their solutions.
9. Explain in detail PDSA cycle (or) Deming wheel (or) Deming cycle and also explain the
continuous process improvements using PDSA Cycle If the Deming wheel rotates, improvement
is assured. Explain Deming wheel. (Or) Explain on PDSA cycle. (AU May/June 2006 &
Nov/Dec 2011)
10. Explain in detail - 5s
11. Explain in detail Kaizen.
12. List the areas of focus of Kaizen for continuous improvement. (AU Nov/Dec 2011)
13. List out the principles of customer/Supplier Relationships. (AU Nov/Dec 2006 May/June
2012)
14. List out the conditions for selection and evaluation of suppliers. (AU May/June 2012)
15. i) Describe briefly any eight criteria that need to be considered white developing
performance measures in organizations.
16. What are the various types of teams? Explain their functions. (AU Nov/Dec 2007)
17. Indicate any two items that can be measured under the following titles in an organization.
UNIVERSITY QUESTIONS
1. a) What are the customer perceptions of quality? Explain. (A.U May/June 2006,09&10)
b) Explain the service quality with its characteristics and expectations. (A.U May/June 2006)
2. a) Explain the basic techniques used for measuring performance.
b) If the Deming wheel rotates, improvement is assured. Explain Deming wheel. (A.U
May/June 2006&09)
3. a) What are the important factors that influence purchases?
b) How can the organizations use customer feedback to their benefits? Give examples.(A.U
Nov/Dec 2006)
4. a) What are the major benefits of 5S implementation? Explain how are they achieved? (A.U
Nov/Dec 2006)
b) What are the principles of customer/supplier relations? (A.U Nov/Dec 2006)
5. a) i) Briefly discuss on customer satisfaction & Employee involvement.
ii) Explain on PDSA cycle. (A.U Apr/May 2005)
b) i) Explain on Juran’s ten steps to quality improvement.
ii) Explain continuous process improvement. (A.U Apr/May 2005)
6. a) i)Enumerate any eight actions that an organizations shall take to handle
complaints.
ii) Describe briefly any eight concepts to achieve a motivated workforce
in an organization. (A.U Nov/Dec 2007)
b) i) Indicate any two items that can be measured under the following titles
in an organization:1) Human resources 2) Customers 3) Production
4) Research and Development.
ii) Describe briefly any eight criteria that need to be considered while
developing performance measures in organizations. (A.U Nov/Dec2007)
7. a) i) What are the various types of teams? Explain their functions.
ii) Discuss the roles and responsibilities of team leader, facilitator,
recorder and number.
b) i) Explain in detail the 5S and its benefits. (Nov/Dec 2010)
ii) What is Kaizen? Explain how Kaizen helps in improving quality on a continuous basis.(or)
Explain the concept of Kaizen (A.U Nov/Dec 2007,08 & May/June 2009)
8. Explain the three phases of Juran Trilogy. (A.U May/June 2009) or
Explain Juran Trilogy. (A.U Nov/Dec 2009)
9. Explain supplier rating and relationship development. (A.U Nov/Dec 2008)
10. Discuss about Maslow’s need hierarchy theory and Herzberg’s two factor theory for
motivation. (A.U Nov/Dec 2008)
11. Explain Employee Motivation & Empowerment. (A.U Nov/Dec 2009)
12. Write a brief note on customer retention. (Nov/Dec 2010)
13. List the various responsibilities of senior management. (Nov/Dec 2010)
14. What is meant by recognition in an organisation? (Nov/Dec 2010)
UNIT 3
PART-A
TWO MARKS Q&A
1. What is check sheet?
A check sheet or tally sheet is a from for systematic data gathering and registering to get a
clear view of the facts.
2. When do you use check sheet?
A check sheet is used to indicate the frequency of a certain occurrence.
3. What is histogram?
A histogram is a bar chart or diagram showing a distribution of variable quantities or
characteristics. It is graphical display of the frequency distribution of numerical data.
4. When do you use histogram?
A histogram is used to show clearly where the most frequently occurring values are located
and the data is distributed. It enables the analyst to quickly visualize the features of a complete
set of data.
5. What is cause and effect diagram? When we can use it?
The cause and effect diagram or fishbone diagram is a graphical tabular chart to list and
analyze the potential causes of a given problem.
6. What is control chart? Give its objectives. (AU Nov/Dec 2010)
A Control chart is a graph that displays data taken over time and the variation of the data.
The objective of control chart is to restrict the chance causes of variation by detecting and
eliminating the assignable causes. Two types of control charts are:
Control chart for variables – X , R and chart.
Control chart for attributes – p, np, c and u charts.
7. What is Six Sigma? (AU Nov/Dec 2010,2011)
Six Sigma is similar to Zero Defects (ZD), is a philosophical benchmark or standard of
excellence proposed by Philip Crosby. Six sigma strives for perfection. It allows for only 3.4
defects per million opportunities (or 99.99966 % accuracy).
8. Brief the scope of Six Sigma principle.
It is originated from manufacturing field. Now it is applied to non-manufacturing processes
also. Today one can apply this principle to many fields such as medical and insurance
procedures, services, call centers etc.
9. Define process flow chart.
A process flow chart is a diagrammatic view of the various steps in sequential order that form
an overall process in an organization. The flow charts are used in the quality management for
depicting the processes in an easily understandable form.
10. Differentiate control limits and specification limits.
Control limits are determined using the averages. In other words, control limits are for
averages. Specification limits are permissible variation in the size of the part. In other words,
specification limits are for individual values. These specification limits (tolerance) are provided
by design engineers to meet a particular function.
11. What are the purposes of process capability analysis?
The purposes of process capability are:
To find out whether the process inherently capable of meeting the specified tolerance
limits.
To identify why a process ‘capable’ is falling to meet specifications.
12. What are the various types of control charts for attributes used?
(a) p – Chart: The chart for fraction rejected as non-conforming to specifications.
(b) np – Chart: The control chart for number of non-conforming items.
(c) c – Chart: The control chart for the number of defects.
(d) u – Chart: The control chart for the number of defects per unit in a sample.
13. Write the difference between the defect and the defective. (AU May/June 2006)
An item is said to be defective, if it fail to conform to the specifications in any of the
characteristics. Each characteristic that does not meet the specifications is called defect.
For example, if a casting contains undesirable hard parts, blow holes etc. The casting is
defective and hard parts, blow holes etc are defects.
14. Differentiate between producer’s risk and consumer’s risk.
Producer’s risk: It is the probability of rejecting a good lot which otherwise would have been
accepted. Consumer’s risk: It is probability of accepting a defective lot which otherwise would
have been rejected.
15. In what way matrix data analysis diagram differs from all other management tools?
Matrix data analysis diagram is the only tool among the ‘new seven management tools’
which uses numerical data and produces numerical results.
16. What are the control charts for attributes? (AU Nov/Dec 2006 & May/June 2012)
Attributes refers to those characteristics that conform or do not conform to specifications.
Control charts for attributes monitor the no of defects or fraction defect rate present in the
sample. Types of control charts for attributes are;
np – Chart
P – Chart
C – Chart
U – Chart
17. Mention the measures of central tendency and dispersion. (AU April/May
2005)Measures of Central Tendency:
Mean
Median &
Mode
Measures of Dispersion:
Range
Mean deviation &
Standard deviation
18. Name the steps involved in six sigma. (AU April/May 2005)
1. Define 2. Measure
3. Analyse 4. Improve 5. Control
19. List down the seven tools of quality or old 7 tools. (AU Nov/Dec 2007)
1. Process Flow – diagram
2. Cause & Effect diagram or Fishbone diagram
3. Histogram
4. Pareto diagram
5. Check sheet
6. Scatter diagram &
7. Control Charts.
20. Define the term process capability. (AU May/June 2006,2012&Nov/Dec 09, 10,11)
Process capability may be defined as the “minimum spread of a specific measurement
variation which will include 99.7% of the measurements from the given process”.
Process capability or normal tolerance = 6 0
21. What are the control charts for variables? (AU May/June 2012)
Quality characteristics which can be measured & expressed in specific units of
measurements are called variables. Control charts based upon measurements of quality
characteristics are called as control charts for variables.
X - Chart
R (or) Range Chart
0 (or) SD chart
X chart
MR chart (or) Moring range chart.
PART-B
(1) Explain about the New Seven tools of quality or New Seven Management tools and its
applications in detail. (AU May/June 2006, 2012 &Nov/Dec 2011)
(2) Explain the DMAIC stages of six sigma in process improvement. (AU May/June 2006 ,2012
& Nov/Dec 2007)
(3) Describe in detail about the seven statistical tools of quality. (AU Nov/Dec 2006 & May/June
2012)
(5) Explain the properties of Normal Curve.
(4) Explain briefly about Six sigma implementation.
5) How is pareto analysis done? Explain with an example. (AU Nov/Dec 2006)
UNIVERSITY QUESTIONS
1. How is Process Decision Program Chart(PDPC) used? (A.U May/June 2007)
2. Briefly explain six sigma process models or stages. (A.U May/June 2006,2009)
3. Explain the concept of six sigma with an example. (A.U Apr/May 2005)
4. Explain briefly about six sigma implementation. (A.U Nov/Dec 2005)
5. What are the New Seven Management tools? Explain their applications.
(A.U Nov/Dec 06,07&10, May/June2006,08)
6. Explain the tree diagram and Arrow diagram. (A.U May/June 2009)
7. Differentiate between control charts for variables and control charts for attributes.
(A.U May/June 2009)
8. Define the term process capability. How will you calculate process capability ratio.
(A.U May/June 2009)
9. Discuss about the need, types, construction and applications of control charts.
(A.U Apr/May 2008)
10. Discuss about the need, construction and applications of control charts for variables.
(A.U Nov/Dec 2008)
11. Explain in detail i) process capability ii) six sigma (A.U Nov/Dec 2008)
12. What are the Ishikawa’s Seven Management tools? Explain their construction & applications.
UNIT 4
PART-A
TWO MARKS Q&A
1. What is QFD? (AU May/June 2006)
Quality Function Development (QFD) may be defined as a system for translating consumer
requirements into appropriate requirements at every stage, from research through product design
and development, to manufacture, distribution, installation and marketing, sales and services.
2. What are the objectives of QFD? (AU May/June 2006)
The objectives of QFD are
To identify the true voice of the customer and to use this knowledge to develop products
which satisfy customers.
To help in the organization and analysis of all the pertinent information associated with
the project.
3. What do you mean by House of Quality? (AU Nov/Dec 09)
The primary planning tool used in QFD is the House of Quality (HOQ). The house of
quality converts the voice of the customer into product design characteristics. QFD uses a series
of matrix diagrams, also called ‘quality tables’ that resemble connected houses.
4. What are the four phases of product development in QFD process?
Product planning
Part Development
Process planning
Production planning
5. List out the benefits of QFD. (Or) When QFD is used? (AU Nov/Dec 2006)
QFD is a communication and planning tool that:
Promote better understanding of customer demands.
Improves customer satisfaction.
Promotes team work.
Facilitates better understanding of design interactions.
6. Define quality in terms of Taguchi’s words.
Taguchi defines quality as “the loss imparted by the product to society from the time the
product is shipped”.
7. What are Taguchi methods?
Taguchi methods are statistical methods developed largely by Genichi Taguchi to improve
the quality of manufactured goods.
Taguchi’s principle contributions to statistics are:
Taguchi loss function,
The philosophy of off-line quality control, and
Innovations in the design of experiments.
8. Write down the philosophy of Taguchi’s quality loss function. (AU Nov/Dec 2008)
The loss function philosophy says that for a manufacturer, the best strategy is to produce
products as close to the target as possible, rather than aiming at ‘being within specifications’.
9. State the concept of quality loss function. (AU Nov/Dec 2010)
The essence of the quality loss function (QLF) concept is that whenever a product deviates
from its target performance, it generates a loss to society. This loss is minimal when
performance is right on target, but it grows gradually as one deviates from the target.
10. Define maintenance.
Maintenance is defined as the management, control, execution and quality assurance of
activities which ensure the achievement of optimum availability and performance of a plant in
order to meet business objectives.
11. What are the types of maintenance?
Corrective or Break down maintenance
Scheduled or Routine maintenance
Preventive maintenance
Predictive maintenance
12. What is Corrective or Break down maintenance?
Corrective maintenance implies that repairs are made after the failure of machine or
equipment.
13. What do you mean by scheduled or routine maintenance?
Scheduled maintenance is a stitch-in-time procedure aimed at avoiding breakdowns. This
includes all work undertaken to keep the production equipment in efficient condition. It may
cover periodic inspection, cleaning, lubrication, overhaul, repair, replacement etc.
14. What do you mean by preventive maintenance?
Preventive maintenance is carried out before the failure arises or prior to the equipment
actually breaks down. It is a safety measure designed to minimize the possibility of
unanticipated breakdowns and interruptions in production.
15. Define predictive maintenance.
In predictive technique, on the production of any fault, maintenance is being done. In this
technique, equipments condition is measured periodically or on a continuous basis. This enables
maintenance staff to take a timely action such as equipment adjustments repair overhaul.
16. What is TPM?
Total Productive Maintenance (TPM) is the systematic execution of maintenance by all
employees through small group activities. The dual goals of TPM are zero breakdowns and zero
defects.
17. What are the objectives of TPM or Why TPM is required? (AU Nov/Dec 2010)
The objective of TPM or the necessity of TPM are:
To improve equipment effectiveness.
To achieve autonomous maintenance.
To plan maintenance.
To train all staff in relevant maintenance skills.
To achieve early equipment management.
18. What are the six big losses? Or what are the six major loss areas need to be measured
for implementing TPM?
Total productive maintenance works to eliminate the following six big losses:
1. Breakdowns Long interruptions, expensive repairs
2. Set up and change over Taking much longer than needed
3. Idling and minor stoppages Hard to quantify, add up to big losses
4. Reduced speed Equipment cycle times have gradually deteriorated
5. Defects and rework Quality losses and unhappy customers
6. Start up losses To long to get to steady after a change.
20. What is the concept of ‘true’ TPM?
The concept of ‘true’ TPM is that everyone from the operator to top management is
responsible for maintenance activities.
PART-B
1. Draw the general structure of ‘House of Quality’ and indicate the constituents in it.
2. Explain briefly about Taguchi’s Quality Loss Function. (AU Nov/Dec 2009,2011)
3. Write short notes on TPM. (Or) Explain the concept of TPM (AU May/June2012)
4. Define Quality Function Deployment. Explain the benefits of QFD. (AU May/June 2012)
5. What do you mean QFD Process? Describe the four phases of QFD process. (AU Nov/Dec
2007)
6. What do you infer from the term “total productive maintenance”? Explain the different types
of maintenance techniques.
UNIVERSITY QUESTIONS
1. What are the steps that contain the core Bench marking? (A.U.NOV/DEC 06)
(or)
Explain the basic steps in Benchmarking process (A.U.MAY/JUN05,06, 09)
2. How is the house of quality constructed? Explain with an example. (A.U.NOV/DEC 06)
3. Explain briefly about Taguchi’s Quality Loss Function. (A.U.NOV/DEC 09)
4. Explain the stages of FMEA (A.U.MAY/JUNE05&NOV/DEC 07)
(or)
Explain the step by step procedure to perform design FMEA with
Household Pressure cooker /computer mouse as an example. (A.U.NOV/DEC 06)
5. a. Write short notes on TPM. (A.U.MAY/JUNE05)
b. What are the six major loss areas need to be measured for implementing TPM?
(A.U.NOV/DEC06, 07)
6. Explain the different types of benchmarking.
7. Define Quality Function Deployment. Explain the benefits of QFD.
8. What is meant by house of quality? Sketch the basic structure of house of quality and explain
each section. (A.U.NOV/DEC 07)
(Or) Explain briefly WHATs and HOWs relationship matrix.
(Or) Explain briefly the prioritized customer requirements and prioritized technical requirements.
(Or) Explain the step-by-step procedure of the house of quality.(A.U.NOV/DEC09)
9. What do you mean QFD Process? Describe the four phases of QFD process.
(A.U.NOV/DEC07, 08)
10. Write the reasons why benchmarking effort fails
11. Briefly explain the Taguchi’s quality loss function with an illustration.
(A.U.APR/MAY05,08)
12. What do you infer from the term “total productive maintenance”?
Explain the different types of maintenance techniques. (A.U.NOV/DEC 07)
13. Explain the eight pillars of TPM. (A.U.APR/MAY 08)
14. Explain learning the New Philosophy of TPM.
15. Define FMEA. Explain the purposes, benefits and types of FMEA.
(A.U.MAY/JUN06,09 &10)
16. Explain QFD with suitable example. (A.U.MAY/JUN 05,06 &09)
17. Discuss about the objectives, process, outcome and benefits of QFD. (A.U.APR/MAY 08)
18. Discuss about the objectives, process, outcome and benefits of FMEA. (A.U.NOV/DEC 08)
UNIT 5
PART-A
TWO MARKS Q&A
1. What is the need for ISO 9000 and other quality systems? (AU Nov/Dec 2008)
Every organization is concerned with quality of its product or service. To assure the quality
one has to make quality assurance system. Sound quality assurance system. Requires well
defined quality system standards.
Quality and standardization are the two essential pre – requisites for an organization to
market its products and service in the competitive business environment thus quality begins with
standards also the ever – increasing pressure to provided better quality of products services led
to the development of quality standards.
2. What is the Necessity for Documentation?
Proper documentation is the pre-requisite for implementing quality system.
The documentation serves as a reference for the management, the staff and other agencies
whose involvement is essential for implementation for quality system.
3. List the advantages of having a Documented Quality System.(AU Nov/Dec 09)
Documentation serves as a reference.
It brings about clarity of objectives and targets.
It provides standardization in work procedures.
It brings about consistency in operations.
It develops confidence amongst employees.
It generates customer’s confidence.
It provides a basis for continuous improvement etc.
4. Give some pitfalls to successful implementation.
Using a generic documentation program or another organization’s documentation
program.
Over documentation or documentation that is too complex.
Using external consultants with out internal ownership and involvement.
Limiting documentation to text rather than other types if media.
Neglecting to obtain top management involvement.
Developing a system that does not represent what actually occurs.
5. Define Environmental Management System (EMS). (or) Briefly explain the purpose of
an ISO 14000 quality system.
Purpose of EMS – ISO 14000 is “an organization should implement an effective
environmental management system in order to protect human health and the environment from
the potential inputs of its activities. Products and services to assist in maintaining and improving
quality of the environment”. This standard is aimed at providing the requirements for
implementing an effective EMS for organization.
6. Write the Benefits of EMS Certification.
Awareness in the organization about the waste reduction.
Compliance with legislation.
Enhancement of environmental awareness within the organization.
Cost savings due to reduction in usage of resources.
EMS certification is an effective sales tool.
Competitive advantage – business won from Non-ISO 14001 competitors.
A demonstration to stakeholders of environmental commitment of the organization.
Environmental Awards.
7. What are the reasons that the organizations are implementing ISO 14001 certifications?
The organizations are implementing ISO 14001 certifications due to variety of reasons.
Some of them are:
Establishing a uniform approach to meet the company’s environmental policy.
Ensuring that the minimum regulatory requirements are consistently met.
Increasing operational efficiency and minimizing wastages.
Requirement to demonstrate the organization’s commitment to the environment to
stakeholders.
Enhancing relationship building with the local community.
8. How do you integrate ISO 14000 with ISO 9000?
EMS implementation can seem like a time consuming and costly undertaking. The
organizations that have implemented ISO 9000 have a distinct advantage over those that are
unfamiliar with process. Depending on the company 25% to 50% of the requirements may
already be in place. Most registrars encourage organizations to integrate their EMS with their
other management system such as ISO 9000. By integrating two systems there will be less
documentation and lower implementation cost.
9. What do you mean by the term quality system?
The quality system is the organizational structure, responsibilities, procedures, processes
and resources for implementing quality management.
10. What are ISO 9000 and ISO 14000?
ISO 9000 has become an international reference for quality management requirements in
business-to-business dealings.ISO 14000 is for environmental management requirements.
11. What is the function of ISO 9000 family?
The ISO 9000 family is primarily concerned with quality management. This means what
the organization does to fulfill
The customer’s quality requirements.
Applicable regulatory requirements, while aiming to enhance customer
satisfaction.
Achieve continual improvement of its performance in pursuit of these objectives.
12. What is the function of ISO 14000 family?(AU Nov/Dec 2011)
The ISO 14000 family is primarily concerned with environmental management. This
means what the organization does to
Minimize harmful effects on the environment caused by its activities.
Achieve continual improvement of its environmental performance.
13. What are the reasons for implementing a quality system that conforms to an ISO
standard?
User’s experience clearly indicates the several significant improvements in the following
areas:
Improved employee involvement
Improved housekeeping
Improved decision making based on facts and data
Improved customer satisfaction
Improved safe working
Reduced customer complaints
Reduced inspection efforts
Reduced quality cost
14. What are the ISO 9000 standards?
The ISO 9000 standards are a collection of formal international standards, technical
reports, handbooks and web based documents on quality management and quality assurance.
15. Where we can apply the ISO 9000 series of standards?
The ISO 9000 series of standards are applied to any organization, large or small, whether
its product, and whether it is a business enterprise, a public administration or a government
department.
16. What are the benefits of documentation? Or What is need for documentation? (AU
May/June 2006, Nov/Dec 2007)
The need or benefits for documentation are:
Documentation regularizes the method of performing the day-to-day activities.
It provides formats for standardizing practices.
It provides reference for assessing degree of enforcement in practice.
It facilitates troubleshooting for tracing back on the processes
Proper documentation is the pre-requisite for implementing quality system.
The documentation serves as a reference for the management, the staff and other
agencies whose involvement is essential for implementation for quality system.
17. What are the objectives or need of quality audits? (AU Nov/Dec 2010,may/June 2012)
The objectives of quality audit programmes are:
To determine the conformity or non-conformity of the quality system elements with
regard t specified requirements.
To determine the effectiveness of the implemented quality system in meeting specified
quality objectives.
To meet regulatory requirements if applicable.
To permit the listing of the audited organizations quality system in a register for third
party certification.
To evaluate an organization’s own quality system against a quality system standard.
18. What are the documents required for QS 9000 programme?
The minimum seven documents required are:
QS 9000 quality system requirements
Advanced Product Quality Planning (APQP) and Control Plan
FMEA
Measurement System Analysis
Fundamental SPC
Production Part Approval Process (PPAP) Manual
Quality System Assessment (QSA) Manual
19. What are the purposes of ISO 14000 series of standards?
The series of ISO 14000 standards are designed to cover:
Environmental Management Systems
Environmental Auditing
Environmental Performance Evaluation
Life-Cycle Assessment
Environmental Aspects in Product Standards.
20. List out the various product evaluation standards of ISO 14000 series of standards.
The product evaluation standards consist of the following three categories:
Environmental Aspects in Product Standards (EAPS)
Environmental Labels and Declarations (ELD) and
Life Cycle Assessment (LCA)
21. Differentiate the terms Environmental Aspect and Environmental Impact.
Environmental Aspect is defined as an element of an organization’s activities or services
that can interact with the environment. Examples are waste water discharge, air emissions and
energy usage. Environmental Impact is defined as any change, whether adverse or beneficial,
wholly or partially resulting from an organization’s activities, products or services. Examples
are impact on water supply and soil erosion.
22. Contrast Environmental Objective and Environmental Target.
Environmental Objective is an overall environmental goal, arising from the policy
statement that an organization sets for itself. Environmental Target is a detailed performance
requirement and should be quantified when practical.
23. What is meant by environmental policy?
The environmental policy should address the following issues:
Management commitment to continual improvement
Prevention of pollution
Compliance with environmental laws and regulation, cooperation with public
authorities
Creating a framework for setting objectives etc.
24. What are the purposes of the standards ISO 14001:1996, ISO 14004:1996, ISO
14020:2000 and ISO 14040:1997?
ISO 14001:1996 – gives the elements that organizations are required to conform to get
registration certificate.
ISO 14004:1996 – provides supplementary material for EMS. It is only for information
and not used for registration.
ISO 14020:2000 – provides guidance on the goals and principles that should be used in
all labeling programs.
ISO 14040:1997 – provides an overview of the practice, applications and limitations of
life cycle assessment.
25. What is the equivalent Indian standard for ISO: 8402? (AU April/May 2005)
The equivalent Indian standard for ISO: 8402 is IS 13999. The ISO: 8402 series of
standards give the definitions of various terms such as quality, inspection, reliability, grade
and quality assurance used in the development of standards on quality systems.
26. What is NCR. (AU Nov/Dec 2008)
NCR means Non-Conformance Report. During ISO certification, the things which do
not comply the ISO requirements are reported in the format known as NCR.
27. Define quality audit. (AU April/May 2005,Nov/Dec 2011)
A quality system audit is defined as “a systematic and independent examination to
determine whether quality activities and related results comply with planned arrangements,
whether these arrangements are implemented effectively and whether these are suitable to
achieve objectives.”
28. Mention the features of quality audits.( AU Nov/Dec 2010)
The features of quality auditing are as follows:
The quality audit typically apples to quality systems or elements such as processes, products
or services. Such audits are often called quality system audits, process quality audits,
product quality audit and service quality audit respectively.
Quality audits are carried by the staff who are not directly responsible in the areas being
audited. But preferably auditors should work in cooperation with relative personnel.
Quality audit is an information gathering activity. It is not a ‘police’ kind of activity.
Quality audits may be conducted for internal or external purposes. They need not cover
whole quality system at once, but may cover elements of it.
29. What are the stages of audit? (AU May/June 2007)
The four stages of the auditing are
1. Audit planning
2. Audit performance
3. Audit reporting
4. Audit follow up
30. Explain the need for ISO 14000 quality systems. (AU April/May2008)
Purpose of ISO 14000 is that “an organization should implement an effective environmental
management system in order to protect human health and the environment from the potential
inputs of its activities. The series of ISO 14000 standards are designed to cover:
Environmental Management Systems
Environmental Auditing
Environmental Performance Evaluation
Life-Cycle Assessment
Environmental Aspects in Product Standards.
PART-B
1. Explain ISO 9000 Family of standards and the benefits of its certification. (Or )Describe the
purpose and the intent of the ISO 9000:2000 program. What are the advantages of becoming
ISO 9000:2000 certified companies? (AU Nov/Dec 2010,2011)
2. Explain the elements of ISO 9000:2000 Quality system. (AU Nov/Dec 2006)
Explain the requirements of ISO 9000:2000 Quality system. (or)
Explain the special clauses of ISO 9000:2000 Quality system.
3. Explain briefly about the implementation (OR) Steps to registration of Quality Management
System. (Or) Discuss the implementation of ISO 9000:2000 quality system. (or) Consider a
company involved in testing the strengths of components.
4. Define Quality Auditing. What are the features, types and objectives of quality audit?
6. Explain the concept and requirements of ISO 14001 QS. (AU May/June 2006 &Nov/Dec
2007, 2008, 2009 )
UNIVERSITY QUESTIONS
1. What are the common elements of quality management systems (QMS) and Environmental
management systems (EMS)? Explain them.
2. Enumerate briefly all the requirements of environmental management Systems (EMS) or ISO
14000? (AU.MAY/JUN2006 &09)
3. Discuss in detail the environmental management systems model with a block diagram?
(AU.NOV/DEC2007)
4. Explain briefly about EMS documentations and EMS records.(or) With the aid of a pyramidal
diagram describe the documentation hierarchy stipulated in ISO 14001 standard
(AU.NOV/DEC2007)
5. Enumerate in detail ISO 14000 family of standards.
6. Enumerate the basic approach to EMS .showing an EMS model.
7. Explain ISO 14000 with an industrial application (AU.APR/MAY2005)
8. Explain briefly the scope on ISO14001
9. Explain the concepts o ISO 14001 QS.
10. Explain the implementation and operation of ISO14001.
11. a) Describe in detail the requirements (major elements)of ISO14000 Standards and its
benefits.
b) Explain about the documentation process in ISO-9000:2000 quality system.
(AU.MAY/JUN2006& NOV/DEC2008)
12. Tabulate the various ISO14000 series of standard indicating designation.
13. Explain the following terms:
(a) Environment (b) Environment aspect (c) Environment impact
(d) Environment policy (e) Environment objective
14. List the benefits that could be realized by implementing ISO 14000 quality
Systems. (Or) Enumerate any eight key organization benefits achievable on
implementing ISO 14001 based system. (AU.NOV/DEC2007)
15. Explain the steps followed to get ISO-9000 certification for an educational institute.
(AU.APR/MAY2005)
16. What are the elements of ISO-9000:2000 quality system.
(AU.APR/MAY2005&NOV/DEC2006,07)
17. Define quality system and explain the evolution of ISO-9000.
(AU.APR/MAY2005)
18. What are the objectives of ISO-9000. (AU.NOV/DEC2006)
19. a) What is the registration process of ISO-9000? What will the auditors might ask?
b) Explain in detail different types of quality audits.
(AU.NOV/DEC2006 &MAY/JUN2006)
20. Contrast between internal audit and external audit. (AU.MAY/JUN2006 &09)
21. a) Explain about quality system auditing.
b) Discuss the steps in implementation of ISO-9000:2000 quality system.
(AU NOV/DEC08,10 &MAY/JUN2009)
22. Explain about the philosophy and the requirements of ISO-9000:2000.
(AU.APR/MAY2008)
23. a) Discuss about the documentation process in ISO-9000:2000 quality system.
b) Explain about the Auditing process and role of external agencies. (or)
Explain how quality audit should be conducted. (or)
Explain the various stages of quality audit.
(AU.APR/MAY2008 & NOV/DEC2009)
25.Explain the concepts of ISO 14001. (AU NOV/DEC2009)
26. Write short notes on documentation of quality system . List the advantages of having
documented quality system. (Nov/Dec 2010
CYCLE TEST-1
PART- A (5*2=10 Marks)
1. What is TQM? (Remembering) (CO 1)
2. Define quality. (Remembering) (CO 1)
3. Explain the Juran’s fitness of quality. (Understanding) (CO 1)
4. List the basic principles of TQM. (Analyzing) (CO 1)
5. What are the dimensions of quality? (Remembering) (CO 1)
ANSWER ALL THE QUESTIONS:
6. Explain the fourteen steps of Deming’s philosophy for improving quality, productivity
and competitiveness. (Understanding) (CO 1) (7)
7. Explain the principles of TQM in detail. (Understanding) (CO 1) (8)
CYCLE TEST-2
PART- A (5*2=10 Marks)
1. Expand 5 S. (Understanding) (CO 2)
2. List the factors that are determining the customer satisfaction. (Analyzing) (CO 2)
3. What are the benefits of 5 S? (Remembering) (CO 2)
4. What is quality planning? (Remembering) (CO 2)
5. Define team and teamwork. (Remembering) (CO 2)
ANSWER ALL THE QUESTIONS:
6. Explain in detail PDSA cycle. (Understanding) (CO 2) (8)
7. Explain in detail Kaizen. (Understanding) (CO 2) (7)
CYCLE TEST-3
PART- A (5*2=10 Marks)
1. List the seven tools of quality. (Analyzing, CO 3)
2. What are the types of check sheets commonly used? (Remembering, CO 3)
3. What are the various types of histogram? (Remembering, CO 3)
4. What is Six Sigma? (Remembering, CO 3)
5. Differentiate between producer’s risk and consumer’s risk. (Analyzing, CO 3)
ANSWER ALL THE QUESTIONS
6. Explain about the New Seven tools of quality or New Seven Management tools and its
applications in detail. (Understanding, CO 3) (8)
7. Explain the properties of Normal Curve. (Understanding, CO 3) (8)
CYCLE TEST-4
PART- A (5*2=10 Marks)
1. What is QFD? (Remembering, CO4)
2. What do you mean by House of Quality? (Remembering, CO4)
3. What are the four phases of product development in QFD process? (Remembering, CO 4)
4. What are Taguchi methods? (Understanding, CO 4)
5. What are the objectives of TPM. (Analyzing, CO 4)
ANSWER ALL THE QUESTIONS
6. Explain the House of Quality matrix and its components. (Understanding, CO 4) (8)
7. Draw the general structure of ‘House of Quality’ and indicate the constituents in it.
(Understanding, CO 4) (7)
CYCLE TEST-5
PART- A (5*2=10 Marks)
1. What is the need for ISO 9000 and other quality systems? (Remembering, CO5)
2. List the advantages of having a Documented Quality System. (Analyzing, CO 5)
3. Define Environmental Management System (EMS). (Remembering, CO 5)
4. What are ISO 9000 and ISO 14000? (Understanding, CO 5)
5. What are the benefits of documentation? (Remembering, CO 5)
ANSWER ALL THE QUESTIONS:
6. Explain ISO 9000 Family of standards and the benefits of its certification.
(Understanding, CO 5) (8)
7. Explain the elements of ISO 9000:2000 Quality system. (Understanding, CO 5) (7)
SEMESTER - VIII
12ME4802 UNCONVENTIONAL MACHINING PROCESSES (Elective) L T P C
3 0 0 3
Objective(s): To learn about the functions and principles of unconventional machining processes.
To gain proficiency of views in machining processes.
UNIT - I INTRODUCTION 08 Hrs.
Need for unconventional machining methods - classification of unconventional machining processes
- considerations in process selection - materials, economic considerations - applications and
limitations - recent developments.
UNIT - II MECHANICAL METAL REMOVAL PROCESSES 09 Hrs.
Abrasive jet machining, water jet machining and abrasive water jet machining - basic principles,
equipments used, process variables, mechanics of metal removal, MRR, application and limitations.
ultrasonic machining - working principles - equipments used - process parameters - MRR -
application and limitations.
UNIT - III ELECTRO - CHEMICAL METAL REMOVAL PROCESSES 09 Hrs.
Fundamentals of electro chemical machining, electrochemical grinding, electro chemical honing and
de burring process, metal removal rate in ECM, tool design, surface finish, accuracy economic
aspects of ECM - simple problems for estimation of metal removal rate. Fundamentals of chemical,
machining, advantages, applications. Maskants – etchants.
UNIT - IV THERMO- ELECTRIC METAL REMOVAL PROCESSES 09 Hrs.
General principle and applications of electric discharge machining, electric discharge grinding and
electric discharge wire cutting processes - power circuits for EDM, mechanics of metal removal,
process parameters, selection of tool electrode and dielectric fluids, surface finish, machining
accuracy and other characteristics of spark eroded surface. . magnetic abrasive finishing, abrasive
flow finishing.
UNIT - V THERMAL METAL REMOVAL PROCESSES 10 Hrs.
Generation and control of electron beam for machining, theory of electron beam machining,
comparison of thermal and non-thermal processes - general principle and application of laser beam
machining - thermal features, cutting speed and accuracy of cut. Application of plasma for
machining, metal removal mechanism, process parameters, accuracy and surface finish and other
applications of plasma in manufacturing industries
Total hours: 45.
ABRASIVE JET MACHINING
2 MARKS Q&A
1. Define AJM?
It is the material removal process where the material is removed or machined by the
impact erosion of the high velocity stream of air or gas and abrasive mixture, which is focused
on to the work piece.
2. How does AJM differ from conventional sand blasting process?
AJM differ from the conventional sand blasting process in the way that the abrasive is much
finer and effective control over the process parameters and cutting. Used mainly to cut hard and
brittle materials, which are thin and sensitive to heat.
3. What are the advantages of AJM process?
1. Low capital cost
2. Less vibration.
3. Good for difficult to reach area.
4. No heat is generated in work piece.
5. Ability to cut intricate holes of any hardness and brittleness in the material.
6. Ability to cut fragile, brittle hard and heat sensitive material without damage.
4. What are the applications of AJM?
1. For abrading and frosting glass, it is more economical than acid etching and
grinding.
2. For doing hard suffuses, safe removal of smears and ceramics oxides on metals.
3. Resistive coating etc from ports to delicate to withstand normal scrapping
4. Delicate cleaning such as removal of smudges from antique documents.
5. Machining semiconductors such as germanium etc.
5. Write the Disadvantages of AJM process?
1. Low metal removal rate.
2. Due to stay cutting accuracy is affected.
3. Parivles is imbedding in work piece.
4. Abrasive powder cannot be reused.
6. Give the formula for find the material remove rate for brittle metal?
MRR = 1.04 ( MV3/2 / ρ1/4H3/4 )
7. Give a summary of the abrasive of their application for different operation?
(1) Aluminum Cleaning, Cutting and Debar
(2) Silicon Carbide. Faster cleaning, Cutting.
(3) Glass Heads Matt polishing, cleaning
(4) Crushed glass Peening and cleaning.
8. Write the formula for find the MRR for ductile materials?
MRR = 0.5 ( MV2 / H)
9. What are the Process parameters affecting the MRR in AJM?
1. Gas Pressure.
2. Velocity of Particles.
3. Abrasive mass flow rate.
4. Mixing ratio.
5. Nozzle Tip Distance.
10. What are the disadvantages of using abrasives again and again?
1. Cutting ability of the abrasives decreases after the large
2. Contamination of wears materials clogging the nozzle and the cutting unit
orifices.
11. What are the different types of nozzles heads used in AJM?
1. Right angle head.
2. Straight head.
12. Why oxygen should not be used in AJM?
Oxygen should not be used because of fire hazard
problem.
13. What are the different types abrasives used in AJM?
Aluminum oxides, silicon carbides, Crushed glass, Sodium bicarbonate, Dolomite.
WATER JET MACHINING
1. What are the properties of water jet machining about effect cutting action?
High pressure, high velocity jet of water.
2. What are the types of units and its purpose used in water jet cutting system?
a. Pump -- to generate high pressure
b. Machining unit-- to actually cut the material with the jet nozzle.
c. Filtration unit -- to clear the water after use.
3. Why we are using the diamond nozzle?
a. High hardness metal
b. Working life is more compared to other jewel nozzle such as ruby or sapphire.
4. Why do you select proper cutting fluid in WJM?
Cutting fluids mainly depends on the operation requirement, quality of finish, cutting
speed and overall cost
5. Does there is any environmental effects while using the water jet machining?
There is no environmental pollution such as dust suspended in the air because the water
jet drains any dust simultaneously when cutting.
6. What are the advantages of WJC over conventional cutting methods?
a. Because of point cutting WJC is able to cut materials almost any pattern.
b. Material loss due to machining is minimum.
c. WJC will not burn surfaces or produces a heat an affected zone.
d. No environmental pollution.
7. What are the applications of WJM?
*Aero space
*Automobile
*Paper pulp industries
8. What are the commonly used additives in WJM?
1. Crly cerine
2. Polyethylene oxide
3.Long chain polymer
9. What is optical tracing system?
It employs an optical scanner that traces a line drawing and produces electronic signals
that control the X-rays.
ULTRA SONIC MACHINING
1. What is ultrasonic machining?
USM is a mechanical material removal process in which the material is removed by
repetitive impact of abrasive particles carried in liquid medium on to the work surface, by a
shaped tool, vibrating at ultrasonic frequency.
2. What are the advantages of USM?
1. High accuracy and good surface finish
2. No heat generation during machining
3. Capability of drilling circular and non-circular holes in very hard
materials.
4. No thmal effects on mechanical work piece.
5. Non-conductive materials can be machined.
3. What are the Disadvantages of USM?
1. Tool wear
2. Frequent turning is required
3. Low material removal rate.
4. Not economical for soft materials.
5. Not suitable for heavy stock removal.
4. What are the applications of USM?
1. Almost all the material can be machined except some soft materials.
2. Diamond, Tungsten, Tungsten carbide, and synthetic ruby can be
successfully machined.
3. USM can be used for drilling, grinding, profiling, coining, threading and
even for welding.
4. For preparing wire drawing dies and tool room items.
5. Used in jewellery for shaping jewels
6. Drilling of screw threads and curved holes in brittle materials.
5. What are the components of USM?
1. Ultrasonic transducer
2. Concentrator
3. Tool
4. Abrasive slurry
5. Abrasive feed mechanism
6. Tool feed mechanism
6. What is ultrasonic transducer?
The device used for converting any type of energy into ultrasonic wavers or vibration is
called ultrasonic transducer.
7. Write short noted on piezoelectric crystals?
Piezoelectric crystals are used for inducing ultrasonic vibrations since they posses the
capability of changing their dimensions to the given electrical energy or in other sense they
have the capability converting electrical energy into mechanical vibrations.
8. What is magnetostrictive effect?
It is the one in which the material changes its dimension is in response to a magnetic field.
9. What are the magnetostrivtive materials employed in USM?
Nickel, Iron – cobalt called as permendum, iron – aluminum called as alter.
10. What is the purpose of concentrator used in USM?
The main purpose of the concentrator is to increase the amplitude of the vibration
obtained from the transducer
11. What is abrasive Slurry?
The abrasive slurry is nothing but a mixture of abrasive grains and the carrier fluid,
generally water.
12. What are the different types of concentrators?
1. Conical Type
2. Exponential type
3. Stepped type.
13. What are the characteristics of carrier fluid?
1. Good wetting characteristic
2. High thermal conductivity
3. Non-toxic and non-corrosive.
4. Should have low viscosity.
14. What are the elements of Carrier Fluid?
1. Act as a coolant.
2. Act as an acoustic bond between the work piece and the tool.
3. Helps efficient transfer of energy.
4. Act as medium to carry the abrasive machined materials and worm abrasives
15. What are the types of feed mechanisms used in USM?
1. Spring type
2. Counter – weight type
3. Motor type
4. Pneumatic and hydraulic type
ELECTRICAL DISCHARGE MACHINING
1.Define electrical discharge machining
EDM is the controlled erosion of electrically conductive materials by the initiation of
rapid and repetitive spark discharge between the electrode tool to the cathode and work to
anode separated by a small gap kept in the path of dielectric medium. This process also called
spark erosion
2. What are functions of dielectric fluid used in EDM?
1. It acts as an insulating medium
2. It cools the spark region and helps in keeping the tool and work piece cool.
3. It maintains a constant resistance across the gap.
4. It carries away the eroded metal particles.
3. Basic requirement of dielectric fluid used in
EDM?
1. Stable Dielectric strength.
2. It should have optimum viscosity.
3. It should have high flash point
4. It should be chemically stable at high temperature and neutral.
5. It should not emit toxic vapors.
4. What the dielectric fluids commonly used in EDM?
1. Petrolium based hydrocarbon fluids.
2. Parafin, white sprite, transformer oil.
3. Kerosine, mineral oil.
5. What are the prime requirements of tool material in EDM?
1. It should be electrically conductive.
2. It should have good mach inability.
3. It should have low erosion rate.
4. It should have low electrical resistance.
6. What is the effect of capacitance in EDM?
Increasing the capacitance causes the discharge to increase and increase both the peak current
and discharge time.
7. Name some of the tool material used in EDM?
1. Copper, brass, alloys of Zinc &tin.
2. Hardened plain carbon steel
3. Copper tungsten, silver tungsten, tungsten
4. Copper graphite and graphite.
8. What is the process parameter efficiency the MRR?
1. Energy discharge
2. Capacitance.
3. Size of work piece.
4. M/c tool design
9. Write the formula for finding the energy discharge in EDM?
10. W=(1/2) X EIT
W - Discharge energy
I - Current,
T - Time,
E - Voltage.
10.How do you increase the inductance of the circuit?
A piece of iron or steel be allowed to lodge between the leads it would increase the
inductance of the circuit and reduce the M/C rate.
11. Define W/T ratio?
It is the ratio of volume of work removed to the volume of tool removed.
12. What is cycle time?
It is the sum of discharge time and waiting time.
13. Define over cut?
It is the discharge by which the machined hole in the work piece exceeds the electrode
size and is determined by both the initiating voltage and the discharge energy.
14. Define Rehardening?
While metal heated to a temperature above the critical and then rapidly cooled by the
flowing dielectric fluid the metal is rehardened.
15. What is recast metal?
Metal heated to a temperature above the melting point and which is not displaced by
the action of the spark discharge, resoldifies as recast metal.
16. Explain electrode wear?
A crater is produced in the electrode, which is likewise dependent on the electrode
material and the energy of the discharge.
17. What are types of power supply circuits used in EDM?
1. R-C circuit.
2. Rotary impulse generator.
3. Controlled pulse (vacuum tube).
4. Oscillator controlled pulse.
18. What are the design factors to be considered while selecting the machine
tool?
1. Number of parts to be produced.
2. Accuracy.
3. Size of work piece.
4. Size of electrode
5. Depth of cavity.
19. Why the servo controlled system is needed in EDM?
EDM requires that a constant arc gap be maintained between the electrode and the work
piece to obtain maximum machining efficiency. Therefore EDM tool in corporate some form of
servo control.
20. Define wear ratio?
Wear ratio=Work piece material removed/Loss of electrode material.
ELECTRO CHEMICAL MACHINING
1) Define ECM?
It is the controlled removal of metals by the anodic dissolution in an electrolytic
medium, where the work piece (anode) and the tool (cathode) are connected to the electrolytic
circuit, which is kept, immersed in the electrolytic medium.
2) Write the Faraday’s first law of electrolysis?
The amount of any material dissolved or deposited is proportional to the quantity of
electrolyte passed.
3) Write the Faraday’s second law of electrolysis?
The amount of different substances dissolved or deposited by the same quantity of
electricity are proportional to their chemical equivalent weight.
4) Write Ohm’s law?
Current, I = V/R
V = Voltage (volt), R = resistance (ohm)
5) What are the factors that influence oxidation in ECM?
(i) Nature of work piece.
(ii) Type of electrolyte.
(iii) Current density
(iv) Temperature of the electrolyte
6) What are the materials used to make the tool electrode?
Copper and copper alloys, titanium, aluminum, brass, bronze, carbon, Monel and reinforced
plastic.
7) What are the main functions of electrolysis in the ECM?
i) For completing the electric circuit between the tool and
the work piece and to allow the reaction to proceed efficiently.
ii) To remove the products of machining from the cutting region.
iii) To carry away the heat generated during the chemical reaction.
iv) To avoid ion concentration at the work piece- tool gap.
8) What are the properties are expected from the electrolysis used in the ECM?
i) High thermal conductivity.
ii) Low viscosity and high specific heat.
iii) Should chemically stable even at high temperature.
iv) Should be non-toxic and non-corrosive.
9) What are the electrolysis commonly used in ECM?
15 -20 % Nacl in water, sodium nitrate, potassium nitrate, sodium sulphate, sodium chromate
and potassium chloride.
10) What are the results which is in improper selection of electrolyte in ECM?
Low machining rate.
Over cut and stray cutting.
11) What are the methods generally used to filter the electrolyte?
(i) Running the system until it is contaminated completely
and replace it.
(ii) Centrifugal separation.
(iii) Sedimentation.
(iv) Use of clarifiers.
12) What are the characteristics of a good ECM tool?
(i) Easily machinable.
(ii) Resistant to chemical reaction.
13) What are the parameters that affect the MRR?
(i) Feed rate. (ii) Voltage. (iii) Concentration of the electrolyte.
(iv) Temperature of the electrolyte. (v) Current density.
(vi) Velocity of the electrolyte.
14) How the current density affect the MRR?
Current density is controlled not only by the amount of current but also by the size of the
gap between the tool and the work piece. A small gap results in high current density, which in
turn produce more material removal.
15) What are the advantages of ECM?
i. ECM is simple, fast and versatile method.
ii. Surface finish can be extremely good.
iii. Fairly good tolerance can be obtained.
16) What are the limitations of ECM?
i. Large power consumption and the related problems.
ii. Sharp internal corners cannot be answered.
iii. Maintenances of higher tolerances require complicated contours.
17) What are the applications of ECM?
ECM is used for sinking, profiling and contouring, multi hole drilling, trepanning,
broaching, honing, steel mill applications, surfacing, sawing, contour machining of hand to hand
machine materials.
ELECTRO CHEMICAL GRINDING
1. Define ECG.
ECG is the material removal process in which the material is removed by the
combination of Electro- Chemical decomposition as in ECM process and abrasive due to
grinding.
2. Which material is used to make the grinding wheel?
Metal bonded diamond (or) Aluminum oxide.
3. What are the important functions of abrasive particles used in ECG?
It acts as insulator to maintain a small gap between the wheel and work piece. They are
electrolysis products from the working area. To cut chips if the wheel should contact the work
piece particularly in the event of power failure.
4. What are the advantages of ECG?
i) No thermal damage to work piece.
ii) Wheel wear is negligible.
iii) No distortion of the work piece.
5. What are the disadvantages of ECG?
High capital costs, because of the special wheel tool. Power consumption is quite high.
Electrolyte is corrosive.
6. What are the limitations of ECG?
1. The work material must be conductive.
2. Not suitable for machining soft material.
3.Require dressing tools for preparing the wheels.
7. What is the application of ECG?
1. Precision grinding of hand metals economically.
2. Grinding Carbide cutting tools inserts. 3. To grind end mill cutters more precisely.
LASER BEAM MACHINING
1. What is Laser?
It is acronym of light amplification by stimulated emission of radiation.
2. What is Maser?
Laser can be melt diamond when focused by lens system. The energy density being of two
order 100,000 KW/cm2. This energy is due to atoms that have light energy level. When such an
atom impinge with electromagnetic waves having resonant frequency.
3. What are the characteristics of Laser beam?
1. Material removal
2. Material shaping
3. Welding
4. Thermo kinetic change.
4. What are the gases commonly used in LASER?
The gases commonly used are:
He, Ne, Argon, Co2 etc.
5. What are the advantages of Laser drilling?
No physical contact between work root pair hence there is no possibility if breakage or wear
of root. Precision location is ensured by focusing of the beam Large aspect ratio can be
achieved.
6. What are the characteristics of Laser used in Laser machining?
1. Can be focused to maximum intensity or to lower intensity as needed.
2. Can be moved rapidly on the work.
3. Remote cutting over long standoff distances.
7. What are the fundamentals of photons used in Laser?
In the Laser the photons are in ground state at 0oC they are brought to the excited state
by means of absorption of energy by temperature change, collision etc.
8. What are the emission lines?
The atoms when they are bringing down goes to the excited state by stimulated
emission and emit photons within 10 nano secs. They have the same wavelength as the excited
photons.
9. What is the Maser principle?
The energy density of laser with 100,000Kw/cm2. The atoms at this state will
impinge with electrons waves having resonate frequency. This is known as maser.
10. What is population inversion?
If the atoms in the excited state are greater than that of the ground state then it is
known as population inversion.
11. How does Laser melting works?
It melts and vaporizes the unwanted material by means of narrow pulsed laser
operating at 2 to 100pilses/sec Because of this high accuracy is not possible to micro sized
holes.
12.What is solid state Laser?
Solid state Laser is the Lasers, which consist of a hot nat, which may be crystalline
solid/ glass, doped with an active material whose atoms provide the lasing action.
PLASMA ARC MACHINING
1. Define plasma.
Plasma is defined as the gas, which has been heated to a sufficiently high temperature
to become ionized.
2. What are the advantages of plasma arc welding?
a. Exothermic oxidation takes place.
b. DC power supply
3. What are the metals that can't be machined by plasma arc machining?
a. Stainless steel
b. Monel
c. Super alloys
4. What is the basic heating phenomenon that takes place in plasma arc welding?
The basic heating phenomenon that takes place at the work piece is a combination of
anode heating due to direct electron bombardment recombination of molecules on the work
piece.
5. How does the basic plasma is generated?
The basic plasma is generated by subjecting a stream of gas to the electron
bombardment of the electric arc.
6. How the initial ionization is accomplished in plasma arc machining?
A high voltage arc established between electrode and nozzle accomplishes initial
ionization.
7. Why does gas formed in plasma do in P.A.M?
This gas stabilizes the arc and prevents it from diverging.
8. How another source of heating achieved in P.A.M?
It is desirable to achieve a third source of heating by injecting oxygen into work area
to take advantage of exothermic oxidation.
9. Write the principle of P.A.M
Once the material has been raised to molten point the high velocity gas stream blows the
material away.
10. Write the circuitry details in PAM.
+ ve terminal connected to work piece and -- ve terminal connected to electrode.
11. Which type of power supply is used in
P.A.M? DC power supply is used.
12. Which part is constricted by plasma?
Nozzle duct is constricted by plasma.
ELECTRON BEAM MACHINING
1. Define EBM?
It is the thermo-electrical material removal process on which the material is removed by the
high velocity electron beam emitted from the tungsten filament made to impinge on the work
surface, where kinetic energy of the beam is transferred to the work piece material, producing
intense heat, which makes the material to melt or vaporize it locally.
2. What is the characteristic of the electron beam?
i. High concentrated energy.
ii. Deep penetration into the metals.
iii. Low distortion.
iv. Any material either conductive or non-conductive can be processed.
3. Why vacuum is needed in EBM?
1) To reduce corrosion
2) To get correct focusing.
4. Write the application of electron beam?
- Thin film machining.
- Surface treatment.
- Engraving metals and non-metals.
- Cutting of materials.
5. What are the main elements of the EBM equipment?
1. Electron Gun.
2. Beam focusing and deflecting units.
3. Work Table.
4. Vacuum chamber
6. What is the function of magnetic lens used in EBM?
It converge the beam into a narrow spot into the work piece.
7. What are the two types of EBM?
(i) Thermal type. (ii) Non-thermal Type.
8. Explain the thermal type EBM?
In this type the electron beam is used to heat the material up to the point where it is
selectively vaporized.
9.Write any four application of EBM?
Micro machining application on materials.
Drilling of apertures for electron microscope.
Drilling of holes in ruby and diamond crystal.
9. Write the Richardson-Dushman Equation.
J=At2 e- (EW/KT)
J = Current Density
A =constant (120 Amphere/cm2deg2)
K =Boltzman Constant (1.3x10-23 J/K)
T = Absolute temperature (Kelvin)
W =work function (Volts)
14. Write general formula for focal length of a magnetic lens?
f/(S + D) = 25V/(NT)2
V =Electron accelerating voltage
NT =Ampere turns in the lens winding
S =pole piece separation,D =Bore diameter
F =focal length
14. What is the drawback of electron beam machining?
One major diameter of electron beam welding has been the requirement of high degree
of vacuum essential or satisfactory operation of this process because of degassing.
UNIT-I
PART-A (2 MARKS)
1. What is necessity for unconventional machining processes?
2. How non-traditional machining processes are classified?
3. Enlist the requirement that demands the use of advanced machining process.
4. Why unconventional mechanical machining process is not so effective on soft metals like
aluminum?
PART-B (16 MARKS)
1. (i) Explain the factors that should be considered during the selection of an appropriate
unconventional machining process for a given job. (8)
(ii) Compare and contrast the various unconventional machining process on the basis of
type of energy employed, material removal rate, transfer media and economical aspects. (8)
UNIT II
PART-A (2 MARKS)
1. Define AJM?
2. How does AJM differ from conventional sand blasting process
3. What are the advantages of AJM process?
4. What are the applications of AJM?
5. Write the Disadvantages of AJM process?
6. Give the formula for find the material remove rate for brittle metal?
7. Give a summary of the abrasive of their application for different operation?
8. Write the formula for find the MRR for ductile materials?
9. What are the Process parameters affecting the MRR in AJM?
10. What are the disadvantages of using abrasives again and again?
11. What are the different types of nozzles heads used in AJM?
12. Why oxygen should not be used in AJM?
13. What are the different types abrasives used in AJM?
14. Reuse of abrasives is not recommended in AJM. Why?
15. What are the properties of water jet machining about effect cutting action?
16. What are the types of units and its purpose used in water jet cutting system?
17. Why we are using the diamond nozzle?
18. Why do you select proper cutting fluid in WJM?
19. Does there is any environmental effects while using the water jet machining?
20. What are the advantages of WJC over conventional cutting methods?
21.What is optical tracing system?
22.What is ultrasonic machining?
23.What are the advantages of USM?
24. What are the Disadvantages of USM?
25. What are the applications of USM?
26. What are the components of USM?
27. What is ultrasonic transducer?
28. Write short noted on piezoelectric crystals?
29. What is magnetostrictive effect?
30. What are the magnetostrivtive materials employed in USM?
31. What is the purpose of concentrator used in USM?
PART-B (16 MARKS)
1. (i) Explain the principle of AJM. Mention some of the specific applications. (6)
(ii) Discuss in detail about the AJM process variables that influence the rate of
material removal and accuracy in the machining. (10)
2. (i) Explain the method of AJM with help of schematic diagram.(10)
(ii) Mention the advantages and limitations of AJM.(6)
3. Explain the process parameters in WJM processs.(16)
4. With neat sketch explain the process of AJM .List its application and limitations.(16)
5. (i) Explain the process parameters that influence WJM.List the applications and
limitations of WJM(10)
(ii) Briefly discuss the application and limitation of WJM.(6)
6. Explain the USM machine setup an discuss various feed mechanisms.(16)
7. (i) Discuss the influence process parameters and applications of USM
(10) (ii) Give a note o the various types of transducers.(6)
UNIT-III
(ELECTRICAL ENERGY BASED PROCESSES)
PART-A (2 MARKS)
1. Define electrical discharge machining?
2. What are functions of dielectric fluid used in EDM?
3. Basic requirement of dielectric fluid used in EDM?
4. What the dielectric fluids commonly used in EDM?
5. What are the prime requirements of tool material in EDM?
6. Name some of the tool material used in EDM?
7. What is the process parameter efficiency the MRR?
8. Write the formula for finding the energy discharge in EDM?
9. What is the effect of capacitance in EDM?
10. How do you increase the inductance of the circuit?
11. Define W/T ratio?
12. What is cycle time?
13. Define over cut?
14. Define Rehardening?
15. What is recast metal?
16. Explain electrode wear?
17. What are types of power supply circuits used in EDM?
18. What are the design factors to be considered while selecting the machine tool?
19. Why the servo controlled system is needed in EDM?
20. Define wear ratio?
21. What are the functions of adaptive control used for EDM?
PART-B (16 MARKS)
1. Explain the process of electrical discharge machining, its process parameters and applications.
2. Describe the wire cut EDM equipment, its working, applications and advantages
3. (i) With the help of neat sketch, Describe the EDM process.(12)
(ii) Explain briefly advantages of wire EDM process.(4)
4. (i) Explain the classification and characteristics of various spark erosion generators. (8)
(ii) With help of neat sketch describe the mechanism of material removal in EDM. (8)
5. (i) Explain the working principle, elements and characteristics of wire EDM. (10)
(ii) Explain how the stratified wire works. Also discuss about the recent developments
in wire EDM. (6)
UNIT-IV
(CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSES)
PART-A (2 MARKS)
1. Define ECM?
2. Write the Faraday’s first law of electrolysis?
3. Write the Faraday’s second law of electrolysis?
4. Write Ohm’s law?
5. What are the factors that influence oxidation in ECM?
6. What are the materials used to make the tool electrode?
7. What are the main functions of electrolysis in the ECM?
8. What are the properties are expected from the electrolysis used in the ECM?
9. What are the electrolysis commonly used in ECM?
10. What are the results which are in improper selection of electrolyte in ECM?
11. What are the methods generally used to filter the electrolyte?
12. What are the characteristics of a good ECM tool?
13. What are the parameters that affect the MRR?
14. How the current density affect the MRR?
15. What are the advantages of ECM?
16. What are the limitations of ECM?
17. What are the applications of ECM?
18. Define ECG.
19. Which material is used to make the grinding wheel?
20. What are the important functions of abrasive particles used in ECG?
21. What are the advantages of ECG?
22. What are the disadvantages of ECG?
23. What are the limitations of ECG?
24. What is the application of ECG?
25. What is the self adjusting feature in ECM?
26. What do you understand by “Etch Factor”?
PART-B (16 MARKS)
1. (i) Describe the chemistry involved in ECM process. (8)
(ii) Briefly discuss about the effect of high temperature and pressure of
electrolyte on the ECM process. (4)
(iii) Discuss about the economics of ECM. (4)
2. (i) Describe the working principle and elements of chemical machining. What
are the factors on which the selection of a resist for use in chemical
machining? (10)
(ii) What are the specific advantages of using chemical machining over electro chemical
machining? Give some of the practical applications of chemical machining process. (6)
3. (i) Explain the principle of ECG with sketch. (8)
(ii) List out the advantage of EGC over conventional grinding.(4)
(iii) Mention the product applcation of ECG.(4)
4.Explain in detail the ECM process with neat sketch and also mention the advantages
and application. (16)
5. (i) Describe the process of electrochemical machining.
(ii) Discuss about the electrochecmical honing and electrochecmical grinding.
UNIT-V
(THERMAL ENERGY BASED PROCESSES)
PART-A (2 MARKS)
1. What is Laser?
2. What are the characteristics of Laser beam?
3. What are the gases commonly used in LASER?
4. What are the advantages of Laser drilling?
5. What are the characteristics of Laser used in Laser machining?
6. What are the fundamentals of photons used in Laser?
7. What are the emission lines?
8. What is the Maser principle?
9. What is population inversion?
10. How does Laser melting works?
11. What is solid state Laser?
12. Define plasma.
13. What are the advantages of plasma arc welding?
14. What are the metals that can't be machined by plasma arc machining?
15. What is the basic heating phenomenon that takes place in plasma arc welding?
16. How does the basic plasma is generated?
17. How the initial ionization is accomplished in plasma arc machining?
18. Why does gas formed in plasma do in P.A.M?
19. How another source of heating achieved in P.A.M?
20. Write the principle of P.A.M
21. Write the circuitry details in PAM.
22. Which type of power supply is used in P.A.M?
23. Which part is constricted by plasma?
24. Describe the commonly used gas mixture in PAM and their corresponding work material
25. Can you machine electrically non-conducting materials using EBM process
26. What is the function of water muffler in PAM?
PART-B (16 MARKS)
1. Explain the process of LBM and PAM with a neat sketchs.
2. (i) Discuss the process parameters of EBM and their influence on machining quality.(8)
(ii) Explain the process capabilities of EBM and PAM..(8)
3. (i) Explain the principle of LBM with neat sketch.(10)
(ii) List out the advantage and limitation of LBM process.(6)
4. (i) Explain the principle of PAM with sketch (10)
(ii) List out the advantage and limitation of PAM process.(6)
5. (i) Mention the application of EBM.(4)
(ii) What is EBM? Sketch its set up an indicate its main parts and explain the principle
of operation.(12)
6. i) Explain the principles and elements of EBM, also how the work table is protected
from getting damaged by electron beam. (8)
(ii) Discuss how the process variables influence MRR, HAZ and pattern generation. (8)
Cycle Test I
Part-A (5x2=10marks)
1. Distinguish between traditional and non- traditional machining process (Remembering CO1)
2.List the important characteristics of unconventional machining process(Understanding CO1)
3.What are the factors to be considered in selection of unconventional machining
process.(Remembering CO1)
4.What is the necessity of unconventional machining process?(Remembering CO1)
5.Classify modern machining processes on the basis of type of energy employed(Analysing
CO1)
Part-B(2x7.5=15marks)
1.State and explain the factors to be considered during the selection of a unconventional
machining process for a given job.(Analyzing CO1)
2.Explain with case study the needs of unconventional machining process(Creating CO1)
Cycle Test II
Part-A (5x2=10marks)
1. Define AJM (Remembering CO2)
2. Name any four process variables that control the material removal rate in AJM
process.(Understanding CO2)
3.List the applications of WJM.(Remembering CO2)
4.Mention the functions of a horn in ultrasonic machining.(Remembering CO2)
5.What are the parameters that influence the MRR in ultrasonic machining process.(Analysing
CO2)
Part-B (2x7.5=15marks)
1. With a schematic diagram, explain the working principle of abrasive machining
process.(Analyzing CO2)
2. What are the factors that affect the performance of WJM process.(Understanding CO1)
Cycle Test III
Part-A(5x2=10marks)
1. List the factors that affect MRR in ECM.(Remembering CO3)
2. What is the advantage of ECG over conventional grinding.(Understanding CO3)
3. Define maskants in Electro Chemical machining.( Remembering CO3)
4. What do you understand by charging of electrolyte.(Understanig CO3)
5. Distinguish between ECM and elctroplating process.(Analysing CO3)
Part-B(2x7.5=15marks)
1. Explain the principle of electro chemical de burring process.(Analyzing CO3)
2. Explain the electro honing process with a neat sketch.(Analyzing CO3)
Assignment-I
Part-A (5x2=10marks)
1. List the desirable properties of a dielectric fluid. (Remembering CO4)
2. Write down the limitations of EDM.(Understanding CO4)
3. What are the roles of dielctric fluid in EDM.( Remembering CO4)
4. What is the servo mechanism in the EDM process.(UnderstanigCO4)
5. Name some of the tool materials used in EDM.(Analysing CO4)
Part-B (2x7.5=15marks)
1. Sketch and explain metal removal in EDM process.(Analyzing CO4)
2. Describe and working principle of Wire cut EDM process.( Analyzing CO4)
Assignment-II
Part-A (5x2=10marks)
1. What do you mean Plasma?(Understanding CO5)
2. What is the advantage of EBM over LBM.(Understanding CO5)
3. Why vaccum id needed in EBM Process.( Remembering CO5)
4. What is the characteristics of electron beam.(Understanig CO5)
5. What are the main elements of the EBM equipment.(Analysing CO5)
Part-B (2x7.5=15marks)
1. What is laser? Explain how it is used to machine the materials.(Analyzing CO5)
2. Discuss the factors that influence the quality of the cut in plasma arc machining
process(AnalyzingCO5)
44
KSRCE/QM/7.5.1/33B/MECH
K.S.R. COLLEGE OF ENGINEERING (Autonomous) R 2012
SEMESTER - VIII
12ME4807 INTERNAL COMBUSTION ENGINES
ELECTIVE
L T P C
3 0 0 3
Prerequisites: Thermal Engineering, Thermodynamics.
Objective : To attain the basic knowledge of internal combustion engines and various
methods to control the pollution.
UNIT - I SPARK IGNITION ENGINES [09 ]
Introduction - mixture requirements - carburetors - fuel injection systems - single point and
multi point injection - stages of combustion - normal, abnormal combustion - factors
affecting knock - measurement of knock - anti knock agent - types of combustion
chambers.
UNIT - II COMPRESSION IGNITION ENGINES [ 09 ]
Introduction - states of combustion - direct, indirect injection systems - combustion
chambers - fuel spray behaviors - spray structure, spray penetration, evaporation - air
motion.
UNIT - III ALTERNATIVE FUELS [ 09 ]
Introduction - Methanol, ethanol, hydrogen, natural gas, biogas, bio diesel, liquefied
petroleum gas - properties, suitability, engine modifications, merits and demerits as fuels.
UNIT - IV EMERGING ENGINE TECHNOLOGIES [09 ]
Introduction - Lean burn engines - stratified charge engines - gasoline direct injection
engine - homogeneous charge compression ignition - plasma ignition - zero emission
vehicle, variable compression ratio engines, and turbocharged engines.
UNIT - V POLLUTANT FORMATION AND CONTROL [ 09 ]
Pollutant - sources and types - formation of NOx - hydrocarbon emission mechanism -
carbon monoxide formation - particulate emissions - effect of pollutant, emission standards
- methods of controlling emissions - catalytic converters, particulate traps.
Total = 45 Periods
Course Outcomes: On completion of this course, the students will be able to
Determine the performance and combustion characteristics of SI engines.
Understand the performance and combustion characteristics of CI engines.
Identify the usage of alternate fuels and power plants for automobiles.
Enhance the efficiency and performance of IC engines.
Determine the emissions from SI and CI engines and its controlling techniques.
Text Books :
1. Ganesan V., “Internal Combustion Engines”, 4th edn., Tata McGraw Hill Pub. Co. Ltd.,
2012.
2. Gupta H. N., “Internal Combustion Engines”, PHI Learning Private Limited, 2012.
45
12ME4807 - INTERNAL COMBUSTION ENGINES (ELECTIVE)
UNIT I – S.I. ENGINES
TWO MARKS:
1. Define heat engine?
Heat engine is device which is used for convert heat energy to mechanical energy is
called heat engine.
2. What is normal combustion in a SI engine?
The combustion of the entire mixture, layer by layer by the moving flame is called
normal combustion in a SI engine.
3. What is called combustion lag?
A ball of fire is produced by the spark. This ball of fire that initiates combustion does
not immediately spread out ward. Before the chain reaction spreads, a short period of slow
burning takes place. This slow burning is called combustion lag.
4. What is called flame front?
The flame as a definite front or boundary (surface area) called flame front. The flame
front separates the burned charge from the unburned charge. The speed which the flame front
travels affects combustion phenomena, development of pressure and production of pressure.
5. What is called detonation or knocking?
When the flame is advancing through the mixture, sometimes the temperature and
pressure conditions in the unburned charge may become severe. Then the rate of chemical
reaction taking place in it may increase so rapidly that it will attain self ignition temperature
and will burn more or less spontaneously. This in turn causes a comparatively high local
pressure and hence sets up a pressure wave. This wave when impinges on this cylinder walls
gives a knocking or metallic sound. This is called detonation or knocking.
6. What are the effects of the knocking combustion?
Knocking combustion may result in the following:
1. Reducing in the power output and efficiency
2. Burning of the piston crown due to increased temperature or due to blow by.
3. Hot gases passed in the piston ring from the piston top to the crank case.
4. The impact of the high pressure wave that is set up might even fracture the
piston crown.
5. Burning of cylinder head valve head.
6. Gumming of the piston rings in the piston grooves leading to ring sticking.
7. Loosing of the valve seat inserts in the cylinder head.
7. What decides the severity of the knock?
Knock in a SI engine is due to the spontaneous combustion of the end mixture. The
severity of knock or knock intensity depends up on the quantity of the end mixture that under
goes spontaneous combustion and the condition of the mixture at the beginning of the
combustion.
8. What are the factors which influence knocking combustion?
Fuel characteristics – molecular structure, self ignition temperature and pre flame
reaction time, flame velocity Condition of the air fuel mixture in the cylinder - air fuel ratio
mixture strength, temperature of the charge, density of the charge, charge distribution.
Compression ratio, ignition timing and combustion chamber.
46
9. What is surface ignition?
Surface ignition caused by a hot spot, may occur before the spark plug ignite the
spark(pre ignition) or after normal ignition (post ignition) it may produce a single flame or
many flame. Surface ignition may result in knock if it occurs after the spark.
10. What is called pre ignition?
Ignition of air fuel mixture by some hot spot which exists within the combustion
chamber, before the occurrence of the spark is called pre ignition.
11. What are the effects of the pre ignition?
1. Steep pressure rise during of the compression stroke itself, leading to work
of compression.
2. Reduced the useful work per cycle
3. Subject the engine components to excessive pressure
4. Increase the heat losses from the engine.
12. What are the advantages of using fuel injection instead of carburetion?
1. Reduce air fuel ratio availability for improved emission control and
performance
2. Improve matching to specific operation requirements, including variations
in the altitude and temperature.
3. Reduce evaporative losses because unlike the convention carburetor, there
is no fuel bowl.
4. Prevents engine stalling due to fuel starvation, stopping and cornering.
13. What is air fuel ratio?
The air fuel is the ratio of the weight of the air to the weight of the fuel supplied to an
engine cylinder during each suction stroke or during a cycle of operation.
14. What is the lean and rich mixture?
If the air fuel ratio supplied to an engine is grater than the theoretical air fuel ratio
then the mixture is said to be lean mixture. If the air fuel ratio supplied to an engine is less
than the theoretical air fuel ratio, then the mixture is called rich mixture.
15. What meant by equivalence ratio?
A equivalence ratio = stoichiometric air fuel ratio/ actual air fuel ratio
When the mixture is rich, the equivalence ratio is greater than one. When the mixture is lean,
the equivalence ratio is less than one.
16 MARKS
1. What are homogeneous and heterogeneous mixtures? In which engines these mixture are
used. Explain?
2. Briefly explain the stages of combustion in SI engines?
3. Explain about the flame front propagation?
4. Explain the various factors that influence the flame speed?
5. Explain about abnormal combustion in SI engine?
6. Explain the phenomena of knock in SI engines?
7. Explain the effects of various engine variables on SI engine knock?
8. What are the various types of combustion chambers used in SI engines? Explain them
briefly?
9. Explain about single point and multi point injection system?
10. Explain the principle of carburetion?
11. What are the factors affecting knock?
12. Explain about the various modern automobile carburetors?
47
UNIT II – C.I. ENGINES
TWO MARKS
1. What are the four stages of combustion in a CI engine?
Ignition delay or delay period , uncontrolled combustion, controlled combustion, after
burning.
2. What are the features which influence the rate of burning of a fuel drop in CI engine?
1. Mode of fuel injection-air injection or airless injection.
2. Direction of fuel injection with respect to air movement.
3. Degree of motion of air particles.
4. Type and design of the combustion chamber.
5. Temperature and pressure of the compressed air.
5. Size of the fuel drop.
3. What is the air fuel ratio in a CI engine?
Air fuel ratio in a diesel engine various from around 100:1 at idle speed to 20:1 at full
load. By comparison, a gasoline engine has an air fuel ratio between18:1 and 12:1 which is
much richer and less fuel efficient.
4. How air movement should be in a CI engine?
The air movement in a diesel engine should not be in irregular in the strict sense. Air
should move in a smooth and ordinary manner at right angle to the direction of the fuel jet.
5. What are the different types of air motion created in a CI engine?
1. Suction swirl
2. Squish
3. Compression turbulence
4. Combustion turbulence.
6. What is squish?
At the end of the compression stroke, piston is brought to within a very small distance
from a cylinder head. This fact causes flow of air from the periphery of the cylinder to its
center and into the recess in the piston crown. This radial inward movement of air is called
squish.
7. How compression swirl is created?
During compression air is forced through a throat, from the cylinder into the
combustion chamber. This throat located tangential to the combustion chamber. As such, the
entering air swirls inside the chamber. The swirl thus created is called compression swirl and
the combustion chamber is called swirl chamber.
8. On what factors, the absolute velocity is compression swirl depend?
Absolute velocity is compression induced swirl depends upon two factors:
1. Piston speed.
2. Ratio of cross sectional areas of piston and throat.
9. What is called uncontrolled combustion in a CI engine?
At the end of the delay period fuel stars burning. At this point, a good amount of fuel
would have already entered and got accumulated inside the combustion chamber. This fuel
charge is surrounded by hot air. The fuel is finely divided and evaporated. Majority of the
fuel burns with an explosion like effect. This instantaneous combustion is called uncontrolled
combustion.
10. What factors decide the rate of burning during controlled combustion?
1. Rate of fuel injection during the period of controlled combustion.
48
2. The fineness of atomization of the injected fuel.
3.The uniformity of distribution of the injected fuel in the combustion
chamber.
4. Amount air distribution of the oxygen left in the combustion space for
reaction of the injected fuel.
11. What is called ignition delay period in a diesel engine?
Delay period is the time interval between the commencement of the fuel injection and
the beginning of the ignition and combustion. The start of combustion is indicated by the
deviation point of the pressure curve above the normal compression pressure. This is usually
about 0.001 second.
12. What is physical delay period?
Physical delay period or the mixing period is the time that elapses between the
beginning of fuel injection and the beginning of pre flame reactions. During this period,
heating and vaporization of the fuel drop and diffusion of air into the vapour layer takes
place. This results in the formation of a suitable mixture of the fuel vapour and air ready for
chemical reaction.
13. What are the factors influencing delay period?
1. Characteristics of fuel(self ignition temperature, volatility and viscosity)
2. Temperature and pressure of the compressed air.
3. Degree of atomization of the injected fuel.
4. Air motion/ turbulence present in the combustion space.
5. Engine speed and injection timing.
14. What are the different types of combustion chambers used in diesel engine?
1. Open or quiescent or direct injection (DI) chamber.
2. Divided or turbulence or swirl combustion chambers
3. Pre combustion chamber.
4. Combustion chamber with an air cell.
5. Combustion chamber with an energy cell.
15. What is open combustion chamber?
Open combustion chamber is one in which all the air meant for combustion is
confined in one space. Hence, this chamber is called direct injection chamber or open
combustion chamber.
16 MARKS
1. What is delay period and what are the factors that affect it?
2. Explain the process of combustion in CI engines?
3. Explain the various stages of combustion?
4. Explain the phenomenon of knock in CI engines and compare it with SI engine knock?
5. Explain with figures the various types of combustion chambers used in CI engines?
6. Explain about fuel spray behavior?
7. Explain about spray structure and spray penetration?
8. Briefly explain about direct injection system?
9. Briefly explain about indirect injection system?
10. What are the factors affecting the delay period
UNIT III – ALTERNATE FUELS
TWO MARKS
49
1. What fuel characteristics are of importance to get good performance in a SI engine?
1. Volatility
2. Detonation and pre ignition characteristics
3. Heat of combustion per unit and volume
4. Heat of evaporation
5. Chemical stability
6. Safety –flash and fire point
2. How the volatility of fuel influences engine performance?
1. Starting characteristics
2. Fuel distribution characteristics
3 .Warm up and acceleration characteristics
4. Vapour lock and percolation characteristics
5. Ice formation tendency
6. Crankcase oil dilution
3. What is octane number of a fuel?
The octane number of a fuel is the percentage by the volume of iso-octane (c8 H18)
and n heptanes which will exhibit the same antiknock characteristics Of the fuel under test
when tested in a standard engine, under a set of standard test conditions.
4. What are the important additives added to gasoline?
Numbers of additives are added to gasoline, during its production in the refinery, to
improve its combustion and other characteristics:
1. Antiknock agent
2. Scavenger
3. Anti oxidant
4. Corrosion inhibitor
5. anti icing agent
5. How diesel fuel viscosity affects fuel injection process?
Viscosity of the fluid is the measure of its resistance to flow or internal friction.
Lubrication, friction between moving parts, their wear and leakage.
6. Why sulfur content should be low in a fuel?
When the fuel is burnt, sulfur present in it produces sulfur dioxide and sulfur trioxide.
Condensation of water vapour in the exhaust will result in the formation of sulfuric acid.
Corrosiveness and acidity will cause wear of various engine parts. So low sulfur content is
most desirable.
7. What is carbon residue of a fuel?
Carbon residue is the carbon left after evaporation and burning off of volatile matter
from a sample of oil by heating. It indicates the tendency of the fuel to form carbon deposits
on engine parts. A maximum carbon residue of 0.10 percent by weight is allowable.
8. What are the different ways of expressing the ignition quality of a fuel?
1. Cetane number of fuel
2. Self ignition temperature of fuel
3. Critical compression ratio
4. Diesel index
5. Aniline point
8. What is cetane number of fuel?
The cetane number of fuel is the percentage by volume of cetane in a mixture of
cetane and alpha methyl naphthalene which will exhibit the same ignition characteristics of
the fuel under test in a standard engine when tested, under a set of standard test condition.
50
9. What is the ignition accelerators added to a fuel?
Ignition accelerators are added to diesel fuels to increase the rate of pre flame reaction
and reduce the ignition lag. Ignition accelerators a) acetone peroxide b) ethyl nitrate
c) isoamyl nitrate.
10. What is the composition of natural gas?
The composition of natural gas varies considerably but usually contains a large
amount of methane, a small amount of ethane, traces of other lighter hydrocarbons and small
amounts of CO2 and N2.
11. What is gasohol?
The gasohol is a mixture of 87 octane unleaded gasoline and ethyl alcohol. The
mixture can contain 2 to 20 percent alcohol. To use this mixture, little or no modification or
adjustment is needed in a gasoline engine.
12. By what techniques alcohols are used in diesel engines?
(Or)
What are the alternate fuels used in CI engines?
1. alcohol/diesel fuel solution
2. Alcohol diesel emulsions
3. Alcohol fumigation
4. Dual fuel injection
13. What are the alternate fuels used in SI engines?
a) Benzol b) acetone c) diethyl ether d) propane e) butane f) natural gas g)
producer gas h) blast furnace gas i) coke oven gas j) alcohol k) hydrogen
14. What are the advantages and disadvantages of LPG?
Advantages:
1. Extremely economical when large distance are covered
2. Emission from an LPG engine are substantially lower than those achieved with
gasoline or diesel fuel.
Disadvantages:
1. Lower cruising ranges and increased fuel volumetric consumption compared to
gasoline
2. Special safety precautions are necessary as LPG is pressurized.
15. What are the important factors which influence the choice of fuel?
1. Viscosity of fuel
2. Flash and fire point of fuel
3. Water and sediment present
4. Pour point of fuel
5. Ash content of fuel
6. Sulfur content of fuel
7. Specific gravity of fuel
8. Corrosiveness and acidity
16 MARKS:
1. Explain the reasons for looking for alternate fuels for IC engines?
2. Explain alcohols as alternate fuels for IC engines bringing out their merits and
demerits?
3. Can alcohol be used for CI engines? Explain?
4. What are the advantages and disadvantages of using hydrogen in SI engine?
5. Explain the 2 methods by which hydrogen can be used in CI engine?
51
6. What is natural gas? What are the advantages and disadvantages of using natural
gas as alternate fuels?
7. Give a brief account of LPG being used as an alternate fuel in SI engine?
8. What are the advantages and disadvantages of using LPG in SI engine?
9. Compare LPG and petrol as fuel for SI engines?
10. Explain the possibilities of using dual fuel systems in engines?
UNIT IV- EMERGING ENGINE TECHNOLOGIES
TWO MARKS:
1. What is a lean burn engine?
Lean burn engine is a layout of Otto cycle engine designed to permit the combustion
of lean air fuel mixtures and to obtain simultaneously low emission values as well as high
fuel economy. The lean burn engine is designed to operate effectively in the air fuel ratio
14:1 to 22:1.
2. What is a stratified charge engine?
Stratification of the charge mixture into distinctly different rich and lean air fuel ratio-
relatively, rich air fuel ratio in the vicinity of the ignition source and a leaner mixture in the
rest of the combustion chamber.
3. What are the advantages and disadvantages of stratified charge engines?
Advantages: 1.It can use a wide range of fuels
2. It has low exhaust emission levels
Disadvantages: 1.For a given engine size, charge stratification result in reduced power
2. Compared to conventional engines, its weight is higher for the
comparable power and its manufacturing cost is also higher.
4. What is the principle of CRDI in gasoline engine?
Gasoline engines were using carburetors for supply of air fuel mixture before the
introduction of MPFI system. But now carburetors are in the use for its simplicity and low
cost. The gasoline is pressurized, and injected via a common rail fuel line directly into the
combustion chamber of each cylinder.
5. What are the advantages of CRDI system?
1. Improved power, increased fuel efficiency and reduced noise.
2. Less emission and reduced particulates in the exhaust.
3. Increase combustion quality due to pilot and post injection.
4. Better pulverization of fuel.
6. What is homogeneous charge compression ignition engine?
HCCI is a form of internal combustion in which well mixed fuel and air are
compressed to the auto ignition temperature of the fuel. The exothermic reaction releases
chemical energy into a sensible form that can be transformed in an engine into work and heat.
7. What are the advantages of HCCI engine?
1. 30 percent fuel savings, while meeting current emissions norms.
2. They are fuel lean and operate at a diesel like compression ratios.
3. It can achieve higher efficiencies than conventional SI engines.
4. Homogeneous mixing leads to cleaner combustion and lower emissions.
5. Peak temperatures are lower than the typical SI engines.
6. No and soot emissions are almost negligible.
8. What are the disadvantages of HCCI engine?
1. High in cylinder peak pressure may cause damage to the engine.
2. Fast heat release and pressure raise rates contribute to engine wear.
3. The auto ignition is difficult to control unlike the SI and CI engine.
52
4. CO emissions are higher compared conventional engine.
9. What are the types of stratified charge engine?
1. Stratification by fuel injection
2. Volks Wagen PCI stratified charge engine
3. Broderson method of stratification.
4. Charge stratification by swirl.
10. Define variable compression ratio engine.
In the VCR engine a high compression ratio is employed for goods stability at low
load operations. Lower compression ratio is used at full load to allow the turbo charger to
boost the intake pressures without increasing the peak cycle pressure.
11. What are the different types of carburetors used in SI engines?
There are three types of carburetors used in SI engines, namely updraft, down draft
and side draft. This classification is based on the direction of air flow into the carburetor and
air fuel mixture flow at the carburetor outlet to inlet manifold.
12. What are stages involved in the process of carburetion?
1. Continuous measuring out of liquid fuel and air in correct proportions for
combustion in the cylinder.
2. Atomization or breaking up the fuel jet into a very fine spray.
3. Intimate and uniform mixing of the fuel spray with the air that flows
through the intake system into the engine cylinder.
4. supplying the necessary latent heat of vaporization to the fuel spray and air
mixture.
13. What are the functions of carburetor?
1. Meter the correct amount of fuel into the air stream, under all operating
conditions
2. Atomize the fuel jet into droplets.
3. Control the mixture flow into the engine cylinder and there by regulate
engine speed and power developed by the engine.
4. Control the vacuum operated devices such as distributor vacuum advance,
charcoal canister valve and others.
14. What are the merits of an open combustion chamber?
1. Heat losses from the air mass to the outside are smaller.
2. Starting is easier.
3. Lower specific fuel consumption.
4. Working components operate at lower temperature.
5. Less heat is rejected to the coolant.
6. Inferior quality fuels can be burned.
15. What are the main drawbacks of the pre combustion chamber?
Heat losses through the orifice are greater during compression. Hence, cold staring is
difficult. Scavenging the pre combustion chamber is difficult. This causes inefficient
combustion. Combustion occurs relatively late in the expansion stroke.
16 MARKS
1. Explain about lean burn engines?
2. Briefly explain about stratified charge engine?
53
3. Explain about gasoline direct injection engine?
4. Explain about homogeneous charge compression ignition engine?
5. Write about plasma ignition?
6. Explain about zero emission vehicles?
7. Write about variable compression ratio engines?
8. Explain about turbo charged engines?
9. Explain types of stratified charged engine?
10. What are the advantages and disadvantages of stratified charge engines?
UNIT V – POLLUTANT FORMATION AND CONTROL
TWO MARKS
1. What are the common SI engine pollutants?
Harmful pollutants emitted by spark ignition engines are: carbonmonoxide, hydro
carbons and oxides of nitrogen.
2. What are the means by which HC concentration in the exhaust of a SI engine can be
reduced?
1. Higher temperature of exhaust gas
2. More oxygen in the exhaust
3. Smaller mass in quench envelope
4. More time for reaction
3. What causes carbon monoxide concentration in a SI engine exhaust?
Carbon monoxide is always present in the exhaust gas due to the dissociation process.
With rich mixtures, the carbon monoxide concentration is further increased due to the
incomplete combustion of carbon.
4. What causes oxides of nitrogen in a SI engine exhaust?
Oxides of nitrogen are formed within the combustion chamber due to dissociation of
the molecular oxygen and nitrogen at the peak combustion temperatures and persist during
expansion and exhausting non equilibrium amounts.
5. What is positive crank case ventilation system?
Positive crank case ventilation system keeps the engine crank case fumes out of
atmosphere. The fumes are left into the inlet manifold. A positive crank case ventilation valve
is commonly used to control the flow of air through the crank case ventilation system.
6. What is exhaust gas recirculation system?
Exhaust gas recirculation system injects small quantities of burnt exhaust gases into
the engine cylinder. This lower combustion temperature and thereby prevents NOx pollution.
7. What is an oxidation catalyst unit?
The oxidation catalyst is used for oxidation of carbon monoxide and hydrocarbons.
For this convertor to work efficiently, the mixture burned by the engine should be lean so that
excess oxygen is available for oxidation.
8. What is a three way catalyst?
In a 3 way catalyst, all the three pollutants, namely CO, HC, and NOx are destroyed
simultaneously. As oxidation and reduction reactions have to take place simultaneously, the
mixture ratio range must be as narrow as possible ensuring neither lean nor rich condition.
This kind of air fuel ratio control is sought to be achieved by electronic closed loop fuel
management system.
9. What are diesel engine pollutants?
54
The visible emissions are smoke and metallic particulates. The invisible emissions are
carbonmonoxide, unburned hydrocarbons including polynuclear aromatics, oxides of
nitrogen, sulphurdioxide, partially oxidized organics such as aldehydes, ketons etc.
10. What causes blue, black and white smoke in SI engine?
1. Blue grey smoke-indicates lubricating oil is entering combustion chamber, may be
due to worn rings, worn cylinders, leaking valve stem seals or other troubles.
2. Black smoke-caused by extremely rich air fuel mixture, and not due to engine
mechanical problem.
3. White smoke-may be due to water condensation on a cool day or may be due to
internal coolant leak into the cylinder.
11. What causes blue, black and white smoke in CI engine?
1. Blue grey smoke-indicates lubricating oil is entering combustion chamber, may be
due to worn rings, worn cylinders, leaking valve stem seals or other troubles.
2. Black smoke-due to injection system problem or low compression which affects
fuel from burning completely.
3. White smoke-due to unburned fuel, cold engine or coolant leaking into the
combustion chamber.
12. What are the methods used for diesel pollution control?
1. NOx emission-cool intake air in the cylinder, late combustion beginning, moderate
air motion.
2. HC emission-minimum lube oil expulsion into the exhaust, complete combustion of
the injected fuel.
3. Particulate emission-fine fuel atomization, intensive mixing of air and fuel, high
excess air, reduced lube oil consumption.
13. What are soluble organic fractions of diesel particulate matter?
Soluble organic fraction of diesel particulate matter is an incompletely burned
substance consisting of high boiling point components of the diesel fuel and the engine
lubricating oil.
14. What are the particulates emitted by SI and CI engine?
The particulates from SI engines are largely sulfuric acid and low molecular weight
organic substances. Diesel particulates are basically carbonaceous with higher molecular
weight organic substances absorbed in the chain type agglomerates.
15. What is crankcase blow by?
The blow by is the phenomenon of leakage past the piston and piston rings from the
cylinder to the crank case. The blow by HC emission is about 20 percent of the total HC
emission from the engine.
16 MARKS
1. Give a brief account of air pollution due to engines?
2. Describe the causes of hydro carbon emissions from SI and CI engines?
3. What are the emissions that come out of engine exhaust?
4. Describe in detail about particulate emission?
5. Give a brief account of other emissions from engine?
6. What is a thermal converter? How does it helps to reduce emissions from engines?
7. What are catalytic convertors? How do they help in reducing HC and CO and NOx
emissions?
8. Give a brief account of emissions from CI engines?
55
9. How can emissions be reduced using chemical methods?
10. What is EGR? And explain how it reduces the NOx emission?
11. What is crank case blowby? How it is controlled?
CYCLE TEST- I Answer all the Questions Part - A 5×2=10 1. What is meant by knocking combustion? May- 2005 2. What are the two main disadvantages of 2-stroke cycle SI engine? Dec-2004 3. Define Pre-Ignition with respect to SI engine? May-2005 4. Why rich mixture is required during idling of SI engines? May-2005 5. Define Equivalence Ratio? Dec-2006
Answer ALL Questions Part - B 2×8,7=15 6. What are the factors affecting knocking in SI engine? &
Explain their influence on knocking with suitable suggestion reduce the same. Dec-2004 7. Describe about the thermodynamic analysis of CI engine combustion.May-2006
CYCLE TEST- II) Answer all the Questions Part - A 5×2=10 1. Define delay period with respect to CI engine combustion? May- 2006 2. Define squish and swirl in CI Engine? May-2006 3. Enumerate the effects of air motion CI engine? May-2007 4. Define “Surface-Volume ratio in a diesel engine? Dec-2005 5. What are the types of injection system? May-2004
Answer ALL Questions Part - B 2×8,7=15 6. Explain the various stages of combustion in CI engine with neat sketch.May-2007 7. Explain the fuel spray characteristics and penetration connected with CI engines? May-2007
CYCLE TEST- III Answer all the Questions Part - A 5×2=10 1. By what method hydrogen can be used as fuel in diesel engine? May- 2007 2. What are the merits and demerits of using Alcohol as a fuel? Dec-2006 3. How LPG can be used as a fuel in diesel engine? May-2005 4. What Is the Effect of adding Methanol on octane number of gasoline? Dec-2004 5. What are the reasons for looking alternative fuels? May-2004
Answer ALL Questions Part - B 2×8,7=15 6. What is meant by emulsion? Explain its types and how it will become a alternative fuel? DEC-2006 7. What are the factors to be considered for engine modification using 100/. Alcohol as alternate fuel? dec-2006
CYCLE TEST- IV
Answer all the Questions Part - A 5×2=10 1. What are the advantages of Lean burn Engines? May-2006 2. What do you mean by HCCI Engines? May-2006 3. What are the advantages of gasoline direct injection?Dec-2004 4. What are the advantages of stratified charge combustion? Mar-2006 5. What is turbo charged engines?
Answer ALL Questions Part - B 2×8,7=15 6. Explain the working of HCCI engine with a neat sketch? May-2005 7. Explain the plasma jet ignition system with sketch? May-2007
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INTERNAL COMBUSTION ENGINES (12ME4807) CYCLE TEST- V
Answer all the Questions Part - A 5×2=10 1. What is an emission standard? why they are formed?Dec-2006 2. What do you mean by the termEGR?May-2007 3. The exhaust emission of methanol gasoline in the midrange.Why?Dec-2005 4. What are treasons for the presence of Hydrocarbons in the exhaust? Dec-2004 5. How do the air/fuel ratios affect the CO Emissions? May-2006
Answer ALL Questions Part - B 2×8,7=15 6. Discuss the various sources of hydrogen emissions in engine and methods to control them?May-2006 7. What are catalytic converters? How they are helpful in reducing HC, CO and NOX emissions? May-2007
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