60 solved GATE ME questions on Manufacturing Processes, drawn from 6 exam years and grouped by year. Every question shows the official answer and a step-by-step solution.
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Identify whether a process is casting, forming, joining, or machining, then apply the relevant mechanics: fluid flow for casting, plastic deformation for forming, heat input for welding, or cutting mechanics for machining. These selected foundations cover core manufacturing topics. They are not a complete syllabus; non-traditional machining and detailed weld metallurgy need separate study.
Our study notes and original examples support the PYQs below; they are not official exam questions or a replacement for the current syllabus.
Chvorinov's rule gives solidification time: t = B(V/A)², where V is casting volume, A is surface area, and B is a mold constant. Thicker sections solidify last. Risers must solidify after the casting; design using (V/A)_riser > (V/A)_casting. Common defects: shrinkage cavities, porosity, hot tears, and cold shuts.
Check yourself: Does the riser have a larger V/A ratio than the section it feeds?
In ideal open-die forging of a cylinder (no friction), force F = σ_y x A, where A is the instantaneous contact area. With friction, F increases. In rolling, draft = reduction in thickness; maximum draft Δh_max = μ²R, where μ is friction coefficient and R is roll radius. Volume constancy applies to plastic deformation.
Check yourself: Have you used the instantaneous area, not the original area, after deformation?
In orthogonal cutting, the material removal rate MRR = v x f x d (cutting speed x feed x depth of cut). Merchant's theory relates shear angle φ to rake angle α and friction angle β: 2φ + β - α = 90° (Merchant's equation). Cutting force F_c = τ_s A_s / (cos(β - α) cos φ), where A_s is shear area.
Check yourself: Are cutting speed, feed, and depth in consistent units for MRR?
Taylor's tool life equation: VT^n = C, where V is cutting speed, T is tool life, and n, C are constants. Higher speed reduces tool life. The economical cutting speed minimizes cost per piece; the speed for maximum production minimizes time per piece. These two optima are different.
Check yourself: Are you optimizing for minimum cost or maximum production rate?
Arc welding heat input H = ηVI/v, where η is efficiency, V is voltage, I is current, and v is welding speed. Higher heat input increases the heat-affected zone width. Joint types include butt, lap, fillet, and corner. Weld defects include porosity, lack of fusion, undercut, and distortion from residual stresses.
Check yourself: Have you included the process efficiency factor η in the heat input calculation?
Original teaching example · not a PYQ
Original example: in orthogonal cutting with cutting speed v = 2 m/s, uncut chip thickness (feed) t₁ = 0.25 mm, and width of cut w = 5 mm, the chip thickness ratio r = 0.4 and rake angle α = 10°. Find the shear angle φ.
Shear angle φ ≈ 22.9°.
A turning operation uses cutting speed V = 100 m/min and the tool has Taylor constants n = 0.25 and C = 300. Find the tool life T in minutes.
T = 81 minutes.
Taylor's equation: VT^n = C. 100 x T^0.25 = 300. T^0.25 = 3. T = 3^(1/0.25) = 3⁴ = 81 minutes.
Supplemental reading, not an official GATE reading list or an endorsement of these notes.
Free supplemental course materials covering casting, forming, machining, and joining processes with lecture notes and problem sets.
This page shows 60 recent questions from the released archive, newest first. For older questions and complete papers, browse all GATE ME papers. Questions can carry more than one subject tag; counts are not marks weightage.
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