ME6023 Manufacturing Technology - I Part - A Unit I: 1. State Any Four Types of Patterns. (May 2006)
ME6023 Manufacturing Technology - I Part - A Unit I: 1. State Any Four Types of Patterns. (May 2006)
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Part - A
Unit I
1. State any four types of patterns. (May 2006)
The various types of patterns which are commonly used are as follows:
Gated pattern
2. Mention any two advantages and disadvantages of die casting. (May 2006)
Advantages:
Limitations:
Moulds are much costlier.
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Investment casting process is also known as Lost-wax process. The term investment refers to
a clock or special covering apparel. In investment casting, the clock is a refractory mould
which surrounds the pre coated wax pattern.
They form core seats in the mould when pattern is embedded in the sand for
mouldmaking.
Core seats are provided to support all the types of cores.
Though the core prints are the part of pattern, they do not appear on the cast part.
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8. What are the advantages and applications of ceramic moulds? (Dec. 2008)
Advantages:
It is less expensive
Intricate objects can be casted.
Castings of thin sections and which do not require machining can be produced.
Applications:
It is mainly used for all material using better ingredient in slurry.
Fettling is the name given to cover all those operations which help the casting to give a
good appearance. It includes the removal of cores, sand, gates, risers, runners and other
unwanted projections from the casting
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Unit II
1. List out any four arc welding equipment. (May 2006)
The most commonly used equipments for arc welding are as follows:
A.C or D.C. machine
Wire brush
Cables and connectors
Ear thing clamps
Chipping hammer
Resistance welding is a process where coalescence is produced by the heat obtained from
resistance offered by the workpiece to the flow of electric current in a circuit of which the
workpiece is a part and by the application of pressure.
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9. What are the diameter and length of the electrodes available in the market? (Dec2009)
Standard length of electrodes is 250 mm, 300 mm and 450 mm.
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Unit III
1. What are the four major drawbacks of hot working? (May 2006)
As hot working is carried out at high temperatures, a rapid oxidation or scale
formation takes place on the metal surface which leads to poor surface finish and
loss of metal.
Due to the loss of carbon from the surface of the steel piece being worked, the
surface
Layer loses its strength.
This weakening of the surface layer may give rise to fatigue crack which results in
failure of the part.
Close tolerance cannot be obtained.
Hot working involves excessive expenditure on account of high tooling cost.
A bloom has a square cross section with minimum size of 150x150 mm and a
billet issmaller than bloom and it may have any square section from 38 mm upto the size
of a bloom.
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The raw material is in slug form which have been turned from a bar or punched
from a strip. By using punch and dies, the operation is performed. The slug is placed in
the die and struck from top by the punch operating at high pressure and speed.
5. Why are a number of passes required to roll a steel bar? (May 2008)
To reduce the thickness and to increase the width of the bar number of passes
arerequired.
Seamless tubing is a popular and economical raw stock for machining because
itsaves drilling and boring of parts. The piercing machine consists of two rapered rolls,
calledas piercing rolls.
That extrusion process which is based both on the use of a lubricant in a viscous
condition at extrusion temperature and on a separation between the lubrication of
thechamber wall and die is called Sejournet process.
The rolls are powered and the workpiece is in due to frictional force between
metaland surface. The torque on the rolls is being zero.
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of a ram or plunger.
Unit IV
1. What is punching operation?
It is the cutting operation with the help of which various shaped holes are produced inthe
sheet metal. It is similar to blanking; only the main difference is that, the hole is
thedesired product and the material punched out to form a hole is considered as a waste.
Superplastic forming is a metalworking process for forming sheet metal. It works upon
the theory of super plasticity, which means that a material can elongate beyond 100% of
its original size.
Press brake (bending brake) is an open frame press used for bending, cutting and
forming. Generally, it handless long work pieces in the form of strips. Usually press
brakes have long dies and suitable and suitable for making long straight line bends.
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Hydro - mechanical forming: In this method , the blank is placed over the punch whose
Electro - hydraulic forming: This method involves the conversion of electrical energy
into mechanical energy in a liquid medium. Electric spark in a liquid produces shock
waves and pressures which can be used for metal forming.
Blanking : It is the cutting operation of a flat metal sheet. The article punched out is
known as blank. Blank is the required product of the operation and the metal left behind
is considered as a waste.
Punching: It is similar to blanking; only the main difference is that, the hole is the
desired product and the material punched out to form a hole is considered as a waste.
In both the sheet metal working processes sheet metal is pressed between a die
and rubber block. Under pressure, the rubber and sheet metal are driven into the die and
confirm to its shape by forming the part.
It is the radius of curvature on inside surface of the bend. If the bend radius is too
small, then cracking of a material on the outer tensile surface takes place. To prevent any
damage to punch and die, the bend radius should not be less than 0.8mm.
It is the ratio of finished shell diameter (d) to the radius of bottom corner(r).
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9. Define Embossing.
With the help of this operation, specific shapes or figures are produced on the
sheet metal. It is used for decorative purpose or giving details like names, trademarks,
specifications, etc. On the sheet metal.
Unit V
1. What are the characteristic of thermoplastics? (May 2006)
Thermoplastics polymers soften when heated and harden, when cooled. These
types of polymers are soft and ductile. They have low melting temperature and can be
repeatedly moulded and remolded to the required shapes.
The following mentioned are the various polymer additives used in practice:
(7) Lubricants.
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Thermosetting polymers (Soften when heated and permanently hardened when cooled)
Rotational moulding process is mostly used for the production of toys in P.V.C
likehorse, boats, etc. Larger containers upto 20 m3 capacity, fuel tanks of automobile are
made from polythene and nylon. This process is also used for production of large drums,
boathulls, buckets, housings and carrying cases.
Blow moulding consists of extrusion of the heated tubular plastic piece called asparison
which is transferred to the two piece mold.
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