Exam Roll No.......•...............0:)

END TERM EXAMINATION(Please write your Exam Roll No.)

EIGHTH SEMESTER [B.TECH.] MAy-JUNE 2012IPaper Code: ETME402 Subject: Quality Control & Quality Assurance JTime: 3 Hours Maximum Marks :75Note: Attempt all five questions including Q.no.1 which is compulsory. Q.no.2 to5 are having two parts each, 'attempt anyone part. Assume missing data if any.

1. Attempt the following:(a) Define the term "quality control". What do you understand by 'quality of design',

. 'quality of c9nformance' and' quality of performance? . [5](b) What do you mean by 'Quality Audit'? Describe various types of it in brief. [4)(c) Make a comparison between attribute control charts and variable control charts. [4](d) Differentiate between continuous and discrete probability distributions. Explain each with

suitable example. [4](e) What do you mean by 'Quality circle' and 'Taguchi's concept of quality'? Explain. [4](f) W'nat do you understand by reliability of a product? Explain the failure pattern for

(2 complex product with suitable figure. [4]

2. Attempt anyone part of the following: [12.5](a) The following table shows the averages and ranges of the spindle diameters in

millimeters for 30 subgroups of 5 items each. For the first 20 samples set up an X chartand an R chart~ Plot the next 10 samples on these charts to see if the process continues"under control" both as average and range. Also find the process capability. [d2 = 2.326,D3=0,D4=2.11].

X R X R X R X R X R45.020 0.375 45.580 0.275 45.320 0.200 45.780 0.275 45.380 0.12545.950 0.450 45.400 0.475 45.560 0.425 45.640 0.225 45.660 0.35045.480 0.450 45.660 0.475 45.140 0.250 45.260 0.150 45.460 0.22545.320 0.150 45.680 0.275 45.620 0.375 45.650 0.200 45.640 0.37545.280 0.200 45.600 0.275 45.800 0.475 45.620 0.400 45.390 0.65045.820 0.250 45.020 0.175 45.500 0.200 45.480 0.225 45.290 0.350

(b) Specifications on a cigar lighter detent are 0.3220 inch and 0.3200 inch. Samples of sizefive are taken every 45 min with the following results (measurements are as deviationsfrom 0.3210 inch in step of 0.0001 inch).

Sample No. xl x2 x3 x4 x5 SampleNo. xl x2 x3 x4 x51 1 9 6 9 6 9 2 0 -1 .3 -1..2 9 4 3 0 3 10' 0 2 -1 -1 23 0 9 0 J ·2 11 .] 02 -1 -1 24 1 1 0 2 1 12 -16 2 0 -4 -15 -3 0 -1 0 -4 13 -6 -3 0 0 -86 -7 2 0 0 2 14 -3 -5 5 0 57 -3 -1 -1 0 -2 15 -1 -1 -1 -2 -18 0 -2 -3 -3 -2

Set up X and R charts and examine the process for statistical control. For sample size offive, A2 = 0.58, D3 = 0 and D4 = 2.11.

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3. Attempt anyone part of the following: [12(a) An analyst takes 20 samples of size 200 each from the output of a final assembly line.

The items in each sample are inspected and the number of defeenves'in eaeh sample arerecorded .. The results are given in the table below. Calculate th¢ average fractiondefective and the control limits for a chart for ,fraction defectives.

Sample No. of Fraction Sample No. of FractionNo . defectives defectives No defectives defectives

1 9 0.045 11 26 0.1302 7 0.035 12 18 0.0903 14 0.070 13 11 0.0554 15 0.075 14 8 0.0405 . 8 0.040 15 10 0.0506 7 . 0.035 16 10 0.0507 9 0.045 17 15 0.0758 11 0.055 18 13 0.0659 16 0.080 19 9 0.04510 12 0.060 20 12 0.060 --'

Suppose that some time after the chart has been established a sample of 300 items istakeJii and. found to contain 25 defectives. Does time result suggest that a satisfactorypopulation mean is being maintained?

(b) The following table gives the numbers of missing rivets noted at aircraft final inspection:

Airplane No. of missing Airplane No. of missing Airplane No. of missingNo. rivets No. rivets No. rivets1 8 . 10 12 19 112 16 11 23 20 93 14 12 16 21 1O4 19 13 '9 22 225 11 14 25 23 76 15 15 15 24 287 8 16 9 25 98 11 17 99 .' " 21 18 14

Plot the control chart for C, frnd the control limits: Also find the modified control limits(if required).

4. Attempt anyone part of the following: [12.5](a) Design a sequential sampling plan for the following specifications: Producer's risk a =

0.05, PI = 0.10 and Consumer's risk p =0.20, P2 = 0,30. Also compute: (i) Averageoutgoing quality when fraction defective p' = Pi ;(ii) .'Minimum number of itemsinspected for .accepting the lot; (iii)· Minimum ••nUIhber of defectives for rejection of thelot; (iv) Average number of items inspected whtm the quality of the lot is Pl.

(b) Explain the, OC curve with reference to sampling inspection and the meaning of theterms: (i) AQL, (ii) LTPD, (iii) IQL, (iv) Producer's risk, and (v) Consumer's risk.

5.. Attempt anyone part of the following:. [12.5](a) What is the need of standardization? Write the features of ISO 9000 series of standards.

What are the advantages an4i disadvantages by becoming an ISO 9000 Company?(b) What are the various steps necessary for obtaining ISO: 9000 standard registration?

Explain them briefly.

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END TERM EXAMINATIONEIGHTH SEMESTER [B.TECH. MAy-JUNE 2012

Paper Code: ETME404 Subject: RoboticsTime: 3 Hours Maximum Marks :75Note: Attempt any five question including Q.no.1 which is compulsory. Select one

question from each unit. Assume missing data if required.

(Please write y(}ur Exam Roll No.) Exam Roll No.•..••••••..•••..•.•...

QI Answer the following questions. in brief:-(a) Who is known as father of Robotics?(b) What definition of Robot is given by RIA?(c) What are three laws of robotics?(d) What is. the envelope of a robot?(e) How do you specify a robot?(f) What is meant by repeatability of a robot?(g) What is point-to-point control in a robot?(h) What is Inverse Kinematics for Robotic Arm?(i) What is a programmable controller?(j) What is RPY Gripper?

(2.5xlO=25)

UNIT-IQ2 (a) What are the basic components of a robotic system? State the main function of each

of the com ponen ts. (4)(b) Sketch the following manipulator configurations:- (4)

(i) TRT:R (ii)TVR:TR(c) Sketch two views to indicate the work envelope of a- (4.5)

(i) Cartesian robot (ii)Cylindrical robot (iii) Polar robotOR

Q3 (a) What are the advantages of hydraulic drive systems over electrical drive system? (4)(b) What is the difference between open loop and closed loop servo system? (4)(c) What are the common sensors used in the robots? State at least five different types

of sensors mentioning the specific attribute to be measured by each. (4.5)

UNIT-IIQ4 (a) Two frames, {A}and {B}are initially coincident. Frame {B}undergoes the following

four motions in sequence with respect to axes of frame {A}:(i) A rotation of eo about z-axis.(ii) A translation of d units along z-axis.(iii)A translation of a units along x-axis.(iv) A rotation of aO about x-axis.Determine the fil.1,~homog~;:neous transformation matrix to describe the frame {B},after the transformation, with respect to the frame {A}. (4.5)

(b) Carry the forward kinematics for a articulated robot arm shown in figure-I, explainthe following steps properly:- (2x4=8)(i) Link coordinate frame at all joints.(ii) D-H parameter table.(iii) D-H Matrices(iv) Position of point P wrt fixed point 0 in terms suitable Link parameters and joint

angles.

Figure-1.articuJated robot arm

OR

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Q5 (a) Develop the Denavit - Hartenberg (D-H) transformation matrix T/_1 for adjacentcoordinate frames, ito i-.1 and discuss its significance in the study of robot armkinematics. (4.5)

(b) Determine the manipulator jacobian matrix for 3-DOF articulated Robotic arm asshown in figure-2. (8)

Elbow JOINTIUPPERA);';<

;;;;;:'"~~.•iJ<.AM\... . . J

pOintO~/

Figure-2: Three axis articulated robot arm

UNIT-IIIQ6 (a) How do you classify a robot end-effector? Mention some of the commercially

available robots using these robot wrists. (4)(b) With the aid of sketches, describe briefly pitch, yaw and roll motions of a robot

wrist. . (4)(c) The end effector of a robot ER VII is rotated about fIxed axes starting with yaw of -

n/2, followed by a pitch of -n/2. What is th~ resulting rotation matrix? (4.5)OR

Q7 The mechanical gripper uses friction to grasp a part weighing 25N. The coefficient offriction between the part and the gripper pad shown in figure-3 is 0.3. The gripper isaccelerating down with a acceleration=9.18m/s2. The diameter of the piston ofpneumatic cylinder is 65mm. Take a factor of safety=1.5 and assume the lengthsLl=60MM, L2=40MM, L3=15MM, L4=45mm.

L, 4 4

Alr·out

Calculate the following:-(a) The gripping force (Pg) to retain the part.(b) Actuating force (P) required to achieve this gripper force.(c) The pressure (Pa) of air needed to operate t~e piston.(d) The power required if the discharge is 0.015m3/sec.

(12.5)

UNIT-IVQ8 (a) Give the name of any.four industries in Delhi/NCR where Robots are being used.

Specify the plant/shop name, type of Robot and applications for each. (4)(b) Write a short note on describing the factorie~ of future. What will be the role of

Humans in this factory? . (4.5)(c) Why Robot is considered as 24/7 worker? (4)

Q9 (a) Write the 10 principle of material handling given by College Industry Council onMaterial Handling Education (CICMHE). (5)

(b) An automated guided vehicle system ha~ an average travel distance perdelivery=200m an average empty travel distance=150m. Load and unload times areeach 24 sec and the speed of AGV=lm/s. How!many vehicles are needed to satisfyadelivery requirement of 30deljhr? Assume availability A=O.95. (7.5)

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END TERM EXAMINATIONEIGHTH SEMESTER B.TECH.] l\-IAV-JUNE 2012

Paper Code: ETME408 Subject: Advanced Methods of ManufacturingTime: 3 Hours Maximum Marks :75

I Note: Attempt any five questions. Assume suitable data if any missing. I

(Please write your Exam Roll No.) Exam Roll No..••......•...•••.....•

Q1

Q2

Q3

Q4

QS

Q6

(a) Name the important factors that should be considered during the selectionof an unconventional machining process for a givenjob. (3)

(b) Discuss the mechanism of material removal in electric-discharge machiningprocess. (6)

(c) What is laser and how is it used to machine the materials? Give the thermalfe~tures and analysis of the laser beam machining. (6)

(a)~hat are the functions of dielectric fluids used in the Electric dischargeiilachining? (3)

(b) In an EDMoperation, with R-Ccircuit, the followingdata are available:-Supply voltage 100V, discharge voltage 75V, resistance (R) lOn, andpercentage of discharge energy used up in metal removal operation 20%.Calculate the time required to drill a 10mm diameter hole in a steel workpiece, having a thickness of 12mm. (Assume C=100/lF) (6)

(c) Make a comparison between laser beam and electron beam machiningprocession the basis of their applications arid limitations. (6)

(a) Write the difference between Transferred and Non-Transferred Plasma ArcSystem. (3)

(b) Sketch and describe any two types of tool feed systems in ultrasonicmachining. (6)

(c) Calculate the time required to drill a 10mm diameter X 100mm long hole inIron plate using ECM. The current is SOAand the electrolyte used is 10%NaClsolution. (Assume atomic weight=SS.8S,valency=2, density=78Sg/cm2)(6)

(a) Discuss the effects of the following parameters on the rate of. materialremoval and surface finish obtainable in ultrasonic machining:- (7)(i) Amplitude and frequency of vibration(ii)Abrasive griz size(iii)Static load

(b) Explain the principle of ECM process. Describe the theoretical relationshipfor the determination of the metal removal rate in ECM. (8)

(a) Describe the principle of flexible manufacturing system with neat sketch.WhyGlothey require major capital investment? (7)

(b) Describe the c1assif1cationof manufacturing systems. Differentiate betweenmass manufacturing and batch manufacturing with the help of examples. (8)

(a) Explain the features of two types of CAPPsystems. (5)(b) Discuss the benefits of Computer-Integrated Manufacturing'operations. (5)(c) Make a comparison between Agile manufacturing and lean manufacturing

on the basis of their process and advantages. (5)

Q7 Write short notes on any three of the followirig:-(a) Concurrent Engineering(b) Cellular Manufacturing(c) Line Balancing(d) Electro Chemical Grinding(e) Abrasive Jet Machining Process

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, -.._..rr""J

(5x3=15)

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END TERM EXAMINATIONEIGHTH SEMESTER [B.TECH.] MAy-JUNE 2012

IPaper Code: ETME412. Subject: IC Engine & Pollution Control ITime: 3 Hours Maximum Marks :75

Note: Attempt five questions Including Q.no.1 which is compulsory. Select one Iquestion from each unit.

(Please write your Exam Roll No.) Exam Roll No ..•..•..•......•.......

Ql (a) Explain engine performance and testing.

(b)Explain Rating of fuels.

(c) Explai!1method for control of NOx.

(d)Write a short note on an influence of engine design.

(e) Write a short note on Plasma Catalyst.

(5x5=25)

Q2

Q3

Q4

Q5

UNIT-IExplain with neat sketch gas chromatography. Also explain all the meritsof flame Ionisation. (12.5)

Explain Ambient air quality standard and also explain air pollution costbenefit analysis. (12.5)

UNIT-IIExplain with neat sketch continuous regeneration traps (CRT)along withmerits, demerits and applications. (12.5)

Explain D.l. and l.D.I engine emission and also explain PM and RSPMemission. (12.5)

UNIT-IIIQ6 (a) Explain various method of stratification.

(b)Explain Gasoline Direct Injection.(12.5)

(,

Q7 (a) Explain with neat sketch catalytic converter along with merits anddemerits.

(b)Explain Blow by control closed PCV system. (12.5)

UNIT-IVQ8 (a) Explain the properties of CNG and LPG fuels. (12.5)

(b)Explain with neat sketch valve timing diagram for two stroke and fourengInes.

Q9 (a) Explain Knocking and its effects. Also explain chemistry of smogformation. (12.5)

(b)Explain Automative. Emission and their role in air pollution alsoexplain Abnormal Combustion.

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END TERM EXAMINATIONExam Roll No...........•....•...••.(Please write YOllr Exam Roll No.)

EIGHTH SEMESTER B.TECH.] MAY-JUNE 2012Paper Code: ETME418 Subject: Reliability & Maintenance ManagementTime: 3 Hours Maximum Marks :75

I Note: Q.no.1 is compulsory. Attempt one question from each unit. I

Ql (a) Define the toll owing terms:(i) Job card(ii) Captive maintenance(iii) Mai'1tainability

.(iv) Reliability(v) Total productive maintenance

(b) Explain computer managed maintenance system.(c) Explain thermography.(d) Explain replacement model with suitable example.(e) What do you mean by reliability and availability function? (5x5=25)

UNIT-IQ2 (a) What do you mean by redundancy. Explain any two types of redundancies. (6)

(b) Explain the concept of bath-tub curve in detail. What do you mean by maintenance planning andcontrol? . (6.5)

ORQ3 (a) A main generator is augmented by a standby generator. The failure rates of both generators follow

exponential distribution laws 'with equal parameters /..)= !v], = 0.05 per hour. Assuming that the decisionswitch is' 100% reliable. Compute the reliability of the system for a 10-hour operation time. (6)

(h) What do you mean by reliability cost trade off and scope ofrcsponsibilitbs in maintenance. (6.5)

(6)(6.5)

•

Q4

Q5

UNIT-II(a) Explain the concept of mean- time- to-failure (MTfF) with suitable example.(b) Derive the expression for reliability in terms of hazard! rate and failure density.

OR(a) Derive the expression for mean.time-to-repair (MTTR). (6)(b) For an emergency operation theatre in a hospital, the power is obtained from the main city supply

through a transformer connected in series. To ensure an uninterrupted supply, an auxiliary generator isalso used with a suitable switch-over. The probabilHy of failure of the city supply is 0.001 and thetransformer reliability is 0.996. The auxiliary power generator has a reliability factor of 0.99. Draw theblock diagram for the system. Construct the fault tree and, based on this, calculate the reliability of thesystem. (6.5)

Q6UNIT-III

(a) List various steps to be followed for proper job planning in detail.(b) Define maintenance organization. List at least ten factors required

organi zation ..

(6)to govern the maintenance

(6.5)

Q7OR

(a) List various steps required to prepare job manual and also write its main uses.(b) Define codification and cataloguing with suitable example. Differentiate

decentralized organization. '

(6)between centralized and

(6.5)

Q8

Q9

UNIT-IV(a) Explain the concept offerrogl'aphy and its types in detail. (6)(b) What are the components and techniques oflubrication monitoring? Explain the concept of FMECA.

. (6.5)OR

(a) Describe terrotechnology, spectroscopy and corrosion monitoring. (6)(b) Explain in detail FMEA including common steps invol~ed in FMEA, FMEA process flow diagram,

failure mode relationship in FMEA, benefits ofFMEA etc. (6.5)

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END TERM EXAMINATIONEIGHTH SEMESTER (B.TECH.] MAy-JUNE 2012

IPaper Code: ETME420 Subject: Power Plant PractiCeS]Time: 3 Hours Maximum Marks :75

I Note: Attempt all questions. Internal choice is indicated. I

(Please wI'ite YOUI' Exam Roll No.) l!.xam Roll No .

Ql Explain any five parts from the fo]J..owing:- (5x5=25)(a) Show the location of evaporator, superheater, reheater, economiss

and Air heat in a typical boiler. Briefly justify their location.(b) List the benefits of high pressure boilers.(c) List merits and demerits of force, natural and induced draft cooling

towers.(d) Explain Regeneration of cation and Anion exchanger.(e) Explain disposal of waste from Nuclear power plant.(f) Explain regenerator used in gas turbine plant.(g) Explain use of indicators, recorders, annunciators in the power plant.

.Q2 Explain with neat diagrams, the processing of coal in the plant. Also,discuss the measures to control spontaneous combustion in coal yard. (12.5)

ORExplain principle of fluidized bed combustion and discuss the working ofcirculating fluidized bed combustor. Also, briefly mention its advantagesand disadvantages. (12.5)

Q3 What are the points of consideration for layout of a plant? Make a layoutof typical turbine hall and justify it on the points written on the responseof first part of this question. (12.5)

ORMake T-S and Schematic diagram for 3 H.P. heater (closed) dne deaeratorand 3 closed LP heaters with one drain cooler and explain working of thissystem. (12.5)

Q4 With the help of T-S and Schematic diagram explain improvement in theperformance of gas turbine plant with intercooling, reheating and alsowith the use of waste heat recovery boiler. (12.5)

ORExplain basics of Nuclear energy, discuss pressurized water reactor.Also, explain Indian strategy to harness nuclear energy in future. Also,list the advantages and disadvantages ofP.W.R. over B.W.R. (12.5)

Q5 Explain various techniques used for control of main steam temperaturecontrol. (12.5)

ORExplain various methods of determination of fixed cost of a plant.Discuss method to compute energy cost. Also, discuss the main pointsfor selection of a site for hydro and thermal power plant. (12.5)

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RS.2000RS.1500RS.500

Expected profit peracre

[-3-]

Wateravailable in acre feet15002000900

Water consumptionin acre feet er acre

543

Useable acera e400600300

ABC

Farm123

The organization is considering three crops for planting which differprimarily in theIr expected profit per acre in their consumption ofwater. Further more, the total acreage that can be devoted to each ofthe crops is limited by the amount of appropriate harvesting<:quipment available:

Crop Minimumacerage

700800300

(

t

In order to maintain a uniform work load among the farms, it is thepolicy of the organization that the percentage of the usable acreageplanted must be the same at each farm. However, any combination ofthe crops may. be grown at any of the farm. The organization wishes toknow how much of each crop should be planted at the respectivefarms in order to maximize expected profit. Formulate this as a linearprogramming problem. . (7.5)

Q6 A reservoir has a live capacity of 870 Mm3. When possible a constantrelease of 150Mm3 is made from the reservoir during all periods forpower generation. If this release is not possible all available water is notpossible, all available for power generation. The head available for powergeneration. The head available for power generation. The head availablefor power generation is given by, where h is the head in meters and S isthe reservoir storage in Mm3. Assuming an initial storage of 500Mm3,

simulate the power generation from the reservoir. The inflow during thesix periods in a year is 75,100, 540, 3280 and O. Assume that overflowsare 1?-0tavailable for power generation. Neglect losses.

ORQ7 With the linear decision, Rt = 8t + (1- a)Qt - bt where, 0 ~ a ~ 1,

obtain the deterministic equivalent .of the storage chance constraint

peSt ~ K) ~ 0.9. Assume that the flows, Qt, follow exponential

distribution with pdf given by f(q) = flexp(-flq) q> 0 . Write down the

deterministic equivalent for a two-period (t=1 and t=2) problem when /3=3for period t=l and (3=5for period t=2. K is the known reservoir capacity.Neglect evaporation losses. (12.51

Q8 (a) Explain the application of linear Iirogramming in multireservoirsystem for irrigation planning. (6)

(b) Explain the application of dynamic programming in steady-statereservoir operating policy for irrigation., (6.5)

ORQ9 Write short notes on any three of the folldwing:- (12.5)

(a) Regional planning models(b) Crop yield optimization(c) Fuzzy rule based reserVoir operation model(d) Reliability-based reservoir sizing

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Northern India Engineering College, New Delhi

Northern India Engineering College, New Delhi

Northern India Engineering College, New Delhi

Northern India Engineering College, New Delhi

Northern India Engineering College, New Delhi

Northern India Engineering College, New Delhi

Northern India Engineering College, New Delhi

Northern India Engineering College, New Delhi

Northern India Engineering College, New Delhi

Northern India Engineering College, New Delhi