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WorksheetsIME_1BIMEK105_ECE 'B'SEC_REFLECTION MODULE 4 & 5
Total questions: 25
Worksheet time: 38mins
Which of the following is an example of a material addition manufacturing process?
Turning
Milling
Casting
Grinding
In 3D printing, which file format is commonly used to represent the 3D model before slicing?
STEP
IGES
STL
DXF
In Fused Deposition Modelling (FDM), the part is built by:
Melting metal powder using a laser
Depositing molten thermoplastic layer by layer
Removing material using a cutting tool
Pressing powder in a die
Which of the following materials is most commonly used in FDM 3D printing?
Aluminium
PLA
Copper
Steel
The main advantage of CNC machines over conventional machines is:
Lower initial cost
Higher dependence on operator skill
Improved accuracy and repeatability
Limited automation
Which CNC lathe operation is used to produce a textured surface for better grip?
Facing
Turning
Knurling
Taper turning
Electric Arc Welding primarily uses which source of heat?
Chemical reaction
Mechanical friction
Electric arc between electrode and workpiece
Laser beam
Which welding process requires a high-vacuum environment?
Electric Arc Welding
Gas Welding
Laser Beam Welding
Electron Beam Welding
Which joining process uses a filler metal with melting temperature below that of the base metal and is commonly used in electronics?
Welding
Brazing
Soldering
Riveting
Green Manufacturing mainly focuses on:
Increasing production speed
Reducing cost only
Minimizing environmental impact and waste
Replacing skilled labor with machines
A company needs to manufacture 5 complex plastic prototypes with internal cavities in a very short time. Which process should be selected and why?
Injection molding – high production rate
CNC machining – high surface finish
3D Printing – no tooling and design flexibility
Casting – low material cost
Poor layer adhesion is observed in an FDM-printed part. Which parameter adjustment would most effectively improve bonding between layers?
Decreasing nozzle temperature
Increasing layer height
Increasing extrusion temperature
Increasing cooling fan speed
A tapered profile is required on a cylindrical job using a CNC lathe. Which operation should be programmed?
Facing cycle
Taper turning cycle
Straight turning cycle
Knurling cycle
A manufacturing plant upgrades from manual lathe to CNC lathe. Which long-term benefit best justifies this transition?
Reduced machine size
Elimination of skilled operators
Improved consistency and repeatability
Reduced power consumption
A thin sheet metal component requires welding with minimum distortion and high speed. Which welding process is most suitable?
Electric Arc Welding
Gas Welding
Shielded Metal Arc Welding
Laser Beam Welding
Why is Electron Beam Welding preferred over Laser Beam Welding for thick sections of reactive metals?
Higher filler metal usage
Operation in atmospheric air
High energy density in vacuum environment
High energy density in vacuum environment
A CNC machining center uses an automatic tool changer (ATC). What is the primary impact of ATC on production?
Increases manual intervention
Improves surface roughness only
Reduces spindle speed
Reduces non-productive time
A manufacturer adopts Green Manufacturing practices by optimizing inventory and reducing excess material storage. Which core principle is being applied?
Recycle
Recover
Reduce
Reuse
Knurling is performed at low spindle speeds mainly to:
Increase material removal rate
Avoid excessive tool wear and surface damage
Increase dimensional accuracy
Improve cutting tool life
A robotic cell is required to perform pick-and-place operations over a large rectangular workspace with high positional accuracy. Which robot configuration is most suitable?
Cartesian robot
Polar robot
Cylindrical robot
Spherical robot
An articulated robot is preferred for welding automobile bodies mainly because:
It has a fixed rectangular workspace
It offers high flexibility and multiple degrees of freedom
It requires simple programming only
It has the lowest initial cost
A robot intended for high-speed assembly of electronic components requires excellent repeatability but moderate accuracy. Which parameter is most critical in this application?
Payload capacity
Repeatability
Workspace volume
Power consumption
A manufacturing unit wants a robot that can safely work alongside humans without physical barriers. Which robot should be selected?
SCARA robot
Cartesian robot
Industrial articulated robot
Collaborative robot (Cobot)
A robot uses revolute joints instead of prismatic joints mainly to:
Increase linear accuracy
Reduce workspace volume
Achieve complex angular movements
Eliminate the control system
Off-line robot programming is especially beneficial when:
Production volume is very low
Robot tasks are simple and repetitive
Production downtime must be minimized
Only one robot is used
