Last Mile Push

 

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Many a time in life, we do not get admission in the college what we want. Sometimes there is a lot of disparity and sometimes there is a little bit of difference between what we have desired and what we have.  The college might be a new one trying to make a mark. In such case, one should look for faculty profile. If they are able then there should be no problem. Most people are generally happy to help but we do not want to take help. How many times have we asked for help in a certain problem? Nil, right. You have to be positive and do your job as a student without sulking.

I have seen students complaining of not getting what they desired. We need to keep in mind that the college education will be common to all and a standardized process. No college in the world can give a customized education. Only a private tutor may be able to do so. If you are interested really in a subject, you have to go alone at first in that direction because it is your only interest. Other classmates may have hundreds other goals and won’t stand with you. A student with a degree means that the student has basic knowledge of the certain field and it is a great filter for higher education or job application. If you want job in a certain sector, you have to push yourself to the last mile to attract an employer for picking you up.  Hence, you have to learn the things of their trade on your own by taking extra courses. Your college may not provide you that knowledge but there is internet and above all Chat GPT now a days to teach you those things in a custom way. The only thing you need is the willingness to learn.

 

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10 Common Manufacturing Process Questions Asked in The Interviews: Theory Series 04

Q1 : What is a manufacturing process? A: A manufacturing process is a series of steps and operations involved in converting raw materials or components into finished products on a large scale.

Q2 : What are the different types of manufacturing processes? A: There are several types of manufacturing processes, including:

1. Casting: It involves pouring molten material into a mold to create a desired shape.
2. Machining: This process uses cutting tools to remove material and shape the final product.
3. Forming: It involves deforming or reshaping materials through processes like bending, rolling, or extrusion.
4. Welding: It joins two or more pieces of material by melting and fusing them together.
5. Assembly: It involves putting together different components to create a finished product.
6. 3D Printing: This additive manufacturing process builds three-dimensional objects by layering materials based on a digital design.

Q3 : What is lean manufacturing? A: Lean manufacturing is a systematic approach that aims to minimize waste and maximize value in the manufacturing process. It focuses on eliminating non-value-added activities, reducing inventory, improving efficiency, and enhancing overall quality.

Q4 : What is Six Sigma in manufacturing? A: Six Sigma is a methodology used in manufacturing to improve the quality of processes and products by identifying and eliminating defects and reducing variability. It employs statistical analysis and problem-solving techniques to achieve a high level of quality control.

Q 5: What is Just-in-Time (JIT) manufacturing? A: Just-in-Time (JIT) manufacturing is an inventory management strategy that aims to produce and deliver products exactly when needed, minimizing inventory and associated costs. It helps reduce waste, lead times, and storage requirements by synchronizing production with customer demand.

Q 6: What is Total Quality Management (TQM)? A: Total Quality Management (TQM) is a management philosophy that focuses on continuously improving the quality of products, processes, and services. It involves all employees in the organization, emphasizing customer satisfaction, employee involvement, and data-driven decision-making.

Q7: What is Computer Numerical Control (CNC) machining? A: Computer Numerical Control (CNC) machining is a manufacturing process that uses computerized control systems to operate machine tools. It allows for precise and automated control of various machining operations, such as cutting, drilling, milling, and turning.

Q8  What is the difference between batch production and mass production? A: Batch production involves producing a limited quantity of identical products in a specific sequence, while mass production refers to the continuous production of large quantities of standardized products. Batch production allows for more flexibility and customization, while mass production focuses on efficiency and cost reduction.

Q9: What is Quality Assurance (QA) in manufacturing? A: Quality Assurance (QA) in manufacturing refers to the systematic processes and activities implemented to ensure that products meet specified quality requirements. It involves inspecting, testing, and monitoring products throughout the manufacturing process to identify and rectify any defects or deviations from quality standards.

Q10: What is a Bill of Materials (BOM)? A: A Bill of Materials (BOM) is a comprehensive list of all the raw materials, components, sub-assemblies, and quantities required to manufacture a specific product. It provides a structured outline for production planning, inventory management, and cost estimation.

Q11: What are the casting defects?

Casting defects are common occurrences in the casting process that result in imperfections or flaws in the final cast product. Some common casting defects include:

1.     Porosity: This defect appears as small voids or bubbles in the cast metal caused by trapped air or gases. It weakens the structure and reduces the material's integrity.

2.     Shrinkage: Shrinkage defects occur when the casting solidifies and cools, causing uneven cooling and resulting in voids or cavities in the casting. It can lead to dimensional inaccuracies and reduced mechanical properties.

3.     Inclusions: Inclusions are foreign materials, such as sand, slag, or oxides, that become trapped in the casting during the pouring process. They can weaken the structure and affect the mechanical properties.

4.     Cold shuts: Cold shuts occur when two streams of molten metal do not fuse properly during the filling process, leading to a visible line or seam in the casting. It weakens the casting and affects its integrity.

5.     Misruns: Misruns happen when the molten metal fails to completely fill the mold cavity, resulting in an incomplete casting. It can be caused by insufficient pouring temperature or inadequate gating system design.

6.     Hot tears: Hot tears are cracks or fractures that occur during the cooling and solidification of the casting due to internal stresses. They are typically caused by inadequate mold rigidity or uneven cooling rates.

7.     Sand wash: Sand wash refers to the surface defect where the mold material is eroded or washed away by the molten metal, leaving a rough or uneven surface finish on the casting.

8.     Surface roughness: Surface roughness defects occur when the mold surface is not smooth or when the casting is not properly cleaned, resulting in an uneven or rough surface finish.

9.     Warpage: Warpage is the distortion or deformation of the casting from its intended shape. It can occur due to uneven cooling, improper mold design, or residual stresses in the casting.

10.  Flash: Flash is an excess metal or thin fins that are formed at the parting line of the mold due to excessive molten metal or mold misalignment. It needs to be removed to achieve the desired casting shape.

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Importance of taking a test

  

On 18 May 2023, I was talking with a group of ex students who had done well. I asked them that how did they do well. Many of them pointed towards online test for various competitive exams. It really helped them. In my school days, I also solved a lot of test papers for the board exams. It made me very confidant before the exam. I had completely solved a thick book while preparing for my 10^th exam. Generally, we forget these good practices when we grow old. These are all tried and tested techniques. In the book called “Brain Rules”, the author is also saying that, we should push ourselves to the same situation as that of exam if we want to do well in such an exam. So, taking online tests and making ourselves accustomed to the situation is very important.  There are thousands of sites which can help in this regard.

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10 Common Fluid Mechanics Questions Asked in The Interviews: Theory Series 03

 

1.     What is viscosity?

Answer: Viscosity is a measure of a fluid's resistance to flow. It determines the internal friction within the fluid. High-viscosity fluids are thick and flow slowly, while low-viscosity fluids are thin and flow more easily.

2.     Define pressure and its units of measurement.

 Answer: Pressure is the force exerted per unit area. It is defined as the ratio of force to the area over which the force is applied. The SI unit of pressure is Pascal (Pa), where 1 Pa equals 1 N/m². Other common units include bar, psi, and atm.

3.     Explain the difference between laminar and turbulent flow.

 Answer: Laminar flow is characterized by smooth and orderly movement of fluid particles in parallel layers, with minimal mixing between layers. Turbulent flow, on the other hand, is characterized by irregular and chaotic fluid motion, involving mixing and eddies.

4.     What is Bernoulli's equation?

Answer: Bernoulli's equation is a fundamental equation in fluid mechanics that relates the pressure, velocity, and elevation of a fluid along a streamline. It states that the total energy of the fluid remains constant along a streamline in the absence of external forces like friction or pumps.

5.     Define Reynolds number and its significance.

Answer: Reynolds number is a dimensionless quantity used to determine the flow regime of a fluid. It represents the ratio of inertial forces to viscous forces in the flow. It helps in predicting whether the flow is laminar or turbulent and provides insights into flow behavior.

6.     Explain the concept of buoyancy.

Answer: Buoyancy is the upward force exerted on an object submerged in a fluid. It is a result of the difference in pressure between the top and bottom surfaces of the object due to the fluid's weight. Buoyancy is governed by Archimedes' principle and plays a crucial role in understanding the behavior of floating and submerged objects.

7.     What is the continuity equation?

Answer: The continuity equation states that the mass flow rate of a fluid remains constant in a steady-state, incompressible flow. It relates the velocity and cross-sectional area of the flow and is based on the principle of conservation of mass.

8.     What is the difference between absolute pressure and gauge pressure?

Answer: Absolute pressure is the total pressure exerted by a fluid, including atmospheric pressure as a reference. It is measured relative to a perfect vacuum. Gauge pressure, on the other hand, is the pressure measured relative to the atmospheric pressure. It does not consider the atmospheric pressure in its measurement.

9.     Define the concept of specific gravity.

Answer: Specific gravity is a dimensionless quantity that represents the density of a substance relative to the density of a reference substance, usually water at a specific temperature. It provides a measure of how much denser or lighter a substance is compared to water.

10.  Explain the working principle of a Venturi meter.

Answer: A Venturi meter is a device used to measure the flow rate of a fluid in a pipe. It consists of a converging section, throat, and diverging section. As the fluid flows through the converging section, its velocity increases, causing a decrease in pressure according to Bernoulli's equation. The pressure difference is measured to determine the flow rate.

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