AKTU Manufacturing Processes · Important Questions 2026Source: ryzenstudy.com PYQs
BME403 Manufacturing Processes Important Questions 2026 (AKTU)
Repeat analysis + most-asked questions, unit-wise
What we did: built from all 4 AKTU Manufacturing Processes papers (2021-22–2025-26): 92 questions grouped into 59 distinct questions, 27 of which were asked in more than one paper.
- of marks were repeat questions
- 66%
- of marks were repeat questions
- questions asked in 2+ papers
- 27
- questions asked in 2+ papers
- papers analysed (2021-22–2025-26)
- 4
- papers analysed (2021-22–2025-26)
- units, mapped to current syllabus
- 5
- units, mapped to current syllabus
How much of the paper repeats?
- Repeats are real: when we checked each newer BME403 paper against the papers before it, on average 66% of its marks were questions already asked in an earlier paper.
- 2024-25 paper: 73% of marks were repeats (9 of 16 repeated questions were in our top list).
- 2025-26 paper: 58% of marks were repeats (5 of 13 repeated questions were in our top list).
- Topic weightage is a guide, not a guarantee: our Tier 1 + Tier 2 topics covered 66% of the next paper's marks — picking the same number of topics at random would have covered about 52%.
Across 10 subjects and 23 papers we tested, 43% of marks repeated earlier questions on average.
1.Unit-wise most-asked questions
Ranked by how many papers asked them, then by how recently. Click a paper to open it.
Unit 1:
21% of past marks| Question | Asked |
|---|---|
| Explain the solidification phenomena in casting. Also describe casting defects and their remedies in brief. | Asked 2× |
| Differentiate between hot working and cold working. Also explain advantages of metal forming processes over other manufacturing processes. | Asked 2× |
| Differentiate between open die forging and closed die forging. | Asked 2× |
| What is shrinkage allowance in casting? | Asked 2× |
Unit 2: (08 Lecture) Metal cutting
21% of past marks| Question | Asked |
|---|---|
| Explain Merchant's force circle diagram and derive Merchant's shear angle relationship. | Asked 3× |
| The tool life equation for HSS tool is expressed by VT^0.15 = C1 and the tungsten carbide tool is expressed by VT^0.25 = C2. If at a speed of 30 m/min the tool life is 120 min, compare the life of the two tools at a speed of 40 m/min. | Asked 3× |
| What do you understand by tool wear? Explain crater wear and flank wear with the help of suitable diagram. | Asked 2× |
| Differentiate between single point and multi point cutting tool. | Asked 2× |
Unit 3: Super finishing
18% of past marks| Question | Asked |
|---|---|
| Write brief notes on all of the following: (i) Honing (ii) Lapping (iii) Superfinishing | Asked 3× |
| Discuss various types of abrasives used for manufacturing of grinding wheels. Also differentiate between dressing and truing. | Asked 2× |
| What is meant by hardness of a grinding wheel? | Asked 2× |
| Explain grade in the grinding wheel. Outline the grinding wheel specification by using the following marking of a grinding wheel as per ISO (see original paper). | Asked 2× |
Unit 4: Arc welding
20% of past marks| Question | Asked |
|---|---|
| What is HAZ in arc welding? | Asked 3× |
| Explain the working of Friction welding process with the help of neat sketch. Also give its advantages and limitations. | Asked 2× |
| Explain the working of TIG & MIG welding in detail with the help of neat sketches. | Asked 2× |
| Explain the principle of Resistance welding process. Discuss how heat balance is achieved in resistance spot welding. | Asked 2× |
Unit 5:
20% of past marks| Question | Asked |
|---|---|
| Write brief notes on the following: (i) Laser beam machining (LBM) (ii) Plasma arc machining (PAM) | Asked 3× |
| Explain the function of electrolyte in ECM. | Asked 2× |
| Write brief notes on the following: (i) Electron beam Machining (EBM) (ii) Electrochemical machining (ECM) | Asked 2× |
| Explain the working principle of Abrasive Jet Machining (AJM) with a neat diagram. Also explain the effect of standoff distance and abrasive grit size on material removal rate in the AJM. | Asked 2× |
2.Topic weightage: which topics carry the marks
Blue = Tier 1 + Tier 2 (topics that carried ~80% of past marks). Grey = the rest. It shows where marks have gone, not a promise of what comes next.
Solidification, shrinkage and risers · U1
9.7% (cum 10%)
LBM, PAM and EBM · U5
6.9% (cum 17%)
AJM, WJM and AWJM · U5
6.7% (cum 23%)
Tool wear and tool life · U2
6.7% (cum 30%)
Orthogonal cutting and force circle · U2
5.6% (cum 36%)
Hot and cold working · U1
5.4% (cum 41%)
Super finishing: honing, lapping, polishing · U3
4.9% (cum 46%)
HAZ and weld decay · U4
4.5% (cum 50%)
Other welding processes · U4
4.4% (cum 55%)
Bulk forming: forging, rolling, extrusion, drawing · U1
4.3% (cum 59%)
Grinding wheel specification · U3
4.3% (cum 63%)
Electrochemical machining · U5
3.8% (cum 67%)
Grinding wheels, abrasives and bonds · U3
3.8% (cum 71%)
TIG and MIG welding · U4
3.4% (cum 74%)
Cutting tools and tool geometry · U2
3.4% (cum 78%)
Wheel wear, dressing and truing · U3
2.4% (cum 80%)
Resistance welding · U4
2.4% (cum 83%)
Arc welding power sources, consumables · U4
2.3% (cum 85%)
CNC, additive manufacturing, rapid prototyping · U2
2.1% (cum 87%)
Chip formation · U2
1.5% (cum 89%)
Surface, cylindrical, centreless grinding · U3
1.5% (cum 90%)
Gas welding and cutting · U4
1.5% (cum 92%)
Turning, drilling, milling operations · U2
1.4% (cum 93%)
Physics of welding, brazing, soldering · U4
1.4% (cum 94%)
Powder metallurgy · U1
1.3% (cum 96%)
Electrical discharge machining · U5
1.3% (cum 97%)
Unconventional vs conventional machining · U5
1.2% (cum 98%)
Chip thickness in grinding · U3
1.2% (cum 99%)
Casting defects and residual stresses · U1
0.7% (cum 100%)
| Topic | Papers | Share |
|---|---|---|
| Solidification, shrinkage and risers · Unit 1 · Tier 1 | 4/4 | 9.7% |
| LBM, PAM and EBM · Unit 5 · Tier 1 | 4/4 | 6.9% |
| AJM, WJM and AWJM · Unit 5 · Tier 1 | 4/4 | 6.7% |
| Tool wear and tool life · Unit 2 · Tier 1 | 4/4 | 6.7% |
| Orthogonal cutting and force circle · Unit 2 · Tier 1 | 4/4 | 5.6% |
| Hot and cold working · Unit 1 · Tier 1 | 4/4 | 5.4% |
| Super finishing: honing, lapping, polishing · Unit 3 · Tier 1 | 4/4 | 4.9% |
| HAZ and weld decay · Unit 4 · Tier 1 | 3/4 | 4.5% |
| Other welding processes · Unit 4 · Tier 2 | 3/4 | 4.4% |
| Bulk forming: forging, rolling, extrusion, drawing · Unit 1 · Tier 2 | 4/4 | 4.3% |
| Grinding wheel specification · Unit 3 · Tier 2 | 3/4 | 4.3% |
| Electrochemical machining · Unit 5 · Tier 2 | 3/4 | 3.8% |
| Grinding wheels, abrasives and bonds · Unit 3 · Tier 2 | 3/4 | 3.8% |
| TIG and MIG welding · Unit 4 · Tier 2 | 2/4 | 3.4% |
| Cutting tools and tool geometry · Unit 2 · Tier 2 | 3/4 | 3.4% |
| Wheel wear, dressing and truing · Unit 3 · Tier 2 | 3/4 | 2.4% |
| Resistance welding · Unit 4 · Tier 3 | 2/4 | 2.4% |
| Arc welding power sources, consumables · Unit 4 · Tier 3 | 2/4 | 2.3% |
| CNC, additive manufacturing, rapid prototyping · Unit 2 · Tier 3 | 3/4 | 2.1% |
| Chip formation · Unit 2 · Tier 3 | 1/4 | 1.5% |
| Surface, cylindrical, centreless grinding · Unit 3 · Tier 3 | 1/4 | 1.5% |
| Gas welding and cutting · Unit 4 · Tier 3 | 1/4 | 1.5% |
| Turning, drilling, milling operations · Unit 2 · Tier 3 | 1/4 | 1.4% |
| Physics of welding, brazing, soldering · Unit 4 · Tier 3 | 2/4 | 1.4% |
| Powder metallurgy · Unit 1 · Tier 3 | 1/4 | 1.3% |
| Electrical discharge machining · Unit 5 · Tier 3 | 1/4 | 1.3% |
| Unconventional vs conventional machining · Unit 5 · Tier 3 | 2/4 | 1.2% |
| Chip thickness in grinding · Unit 3 · Tier 3 | 1/4 | 1.2% |
| Casting defects and residual stresses · Unit 1 · Tier 3 | 1/4 | 0.7% |
3.Paper pattern (2025-26)
| Section | Questions | Rule |
|---|---|---|
| A | 6 × 2 marks | Attempt all |
| B | 5 × 7 marks | Attempt any 3 |
| C | 10 × 7 marks | Attempt any 1 |
4.In the syllabus, never asked yet
Low priority, but read them once — a new paper can always start here.
- Casting processes and patterns · U1
- Plastic deformation and yield criteria · U1
- Sheet metal forming · U1
- Machinability, tool materials, cutting fluids · U2
- Ultrasonic machining · U5
5.Study order
- 1Solidification, shrinkage and risers (Unit 1, Tier 1)
- 2LBM, PAM and EBM (Unit 5, Tier 1)
- 3AJM, WJM and AWJM (Unit 5, Tier 1)
- 4Tool wear and tool life (Unit 2, Tier 1)
- 5Orthogonal cutting and force circle (Unit 2, Tier 1)
- 6Hot and cold working (Unit 1, Tier 1)
- 7Super finishing: honing, lapping, polishing (Unit 3, Tier 1)
- 8HAZ and weld decay (Unit 4, Tier 1)
- 9Other welding processes (Unit 4, Tier 2)
- 10Bulk forming: forging, rolling, extrusion, drawing (Unit 1, Tier 2)
- 11Grinding wheel specification (Unit 3, Tier 2)
- 12Electrochemical machining (Unit 5, Tier 2)
- 13Grinding wheels, abrasives and bonds (Unit 3, Tier 2)
- 14TIG and MIG welding (Unit 4, Tier 2)
- 15Cutting tools and tool geometry (Unit 2, Tier 2)
- 16Wheel wear, dressing and truing (Unit 3, Tier 2)
FAQ
Which units of BME403 carry the most marks?
Unit 1 (, 21% of past marks) and Unit 2 ((08 Lecture) Metal cutting, 21% of past marks).
Do AKTU Manufacturing Processes questions repeat?
Yes. On average 66% of the marks in each newer BME403 paper came from questions already asked in an earlier paper, and 27 questions have appeared in more than one paper.
How is this list made?
Every question from the 4 papers (2021-22–2025-26) was mapped to the current AKTU syllabus and grouped with the same question from other years. Questions are ranked by how many papers they appeared in, then by how recently.
Study this subject
Note: this is based on past AKTU papers, not a guarantee. Questions are mapped to the current syllabus; topics that are no longer in the syllabus are left out.