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ME6023 Manufacturing Technology I

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:

Single piece or solid pattern

Two piece or split pattern

Loose piece pattern

Cope and drag pattern

Gated pattern

2. Mention any two advantages and disadvantages of die casting. (May 2006)
Advantages:

It is a very fast process.

Moulds have longer life.

Better surface can be obtained.

Limitations:
Moulds are much costlier.

This method is not suitable for small quantity production.

Shape and weight of the casting is limited.

3. Write the requirements of good pattern. (May 2007)

Simple in design

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Cheap and readily available

Light in mass
Surface id smooth
Have high strength
4. What is core venting ? (May 2007)
While pouring the mould with molten metal mould walls and cores heat up
rapidlyandreleases large amount of gases. In order to prevent casting defects these gases
must bevented out. For this purpose core venting are used. Core venting are incorporated
in the core box itself.

5. What function of core ? (May 2008)

Functions of core are:
Core provides a means of forming the main internal cavity for hollow casting.
Core provides external undercut feature.
Cores can be inserted to obtain deep recesses in the casting.
Cores can be used to increase the strength of the mould.

6. Which process is called lost waxing method? Why? (May 2008)

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.

7. What is the function of core prints ? (Dec. 2008)

Core prints are basically extra projections provided on the 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.

9. What are the pattern materials? (Dec. 2008)

Wood, metal, plastic, plaster and wax

10. Explain the term fettling. (Dec. 2009)

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

2. What are the special features of friction welding? (May 2007)

Friction welding is a solid state welding process where coalescence is produced
by the heat obtained from mechanically induced sliding motion between rubbing
surfaces.
The work parts are held together under pressure.
Its operating is simple.
Power required for the operation is low.
It is used for joining steels, super alloys, non-ferrous metals and combinations of
metals.

3. Define resistance welding process. (May 2006, May 2007)

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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4. What is the purpose of flux? (May 2008)

It acts as shield to weld.
To prevent atmospheric reaction of molten metal with atmosphere.

5. How can slag inclusions in welding be avoided? (May 2008)

Avoid multi layer welding
Reduce arc length
Increase electrode angle
Avoid using large electrode

6. How does brazing differ from braze welding? (Dec. 2008)

BRAZING BRAZE WELDING

The filler alloy is fed to one or more points

The filler alloy is deposited directly at the
in the assembly and it is drawn into the rest
point where it is desired.
of the joint by capillary action.

7. Why flux is coated on filler rods? (Dec. 2008)

The coating improves penetration and surface finish.
Suitable coating will improve metal deposition rates.

8. What is the application of carburizing flame? (Dec. 2009)

Carburizing flame is generally used for:
Welding of low alloy steel rods
Non-ferrous metals
High carbon steel

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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Standard diameters of electrodes are 1.6,2, 2.5, 3.2, 4,5,6,7,8, and 9 mm

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.

2. Classify the types of extrusion. (May 2006)

Hot extrusion, cold extrusion
Hot extrusion:
Direct extrusion
Indirect extrusion
Tube extrusion

3. What is the difference between a bloom and a billet? (May 2007)

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.

4. What is impact extrusion? (May 2007)

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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.

6. How are seamless tubes produced? (May 2008)

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.

7. What is Sejournet process? (Dec. 2008)

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.

8. What is skew rolling ?(Dec. 2008)

The rolls are powered and the workpiece is in due to frictional force between
metaland surface. The torque on the rolls is being zero.

9. Explain the term Extrusion process. (Dec.2009)

The extrusion process consists of compressing a metal inside a chamber to force it

outthrough a small opening which is called as die. Any plastic material can be
successfullyextruded. A large number of extruded shapes which are commonly used are
tubes, rods,structural shapes and lead covered cables. During the process, a heated
cylindrical billet isplaced in the container and forced out through a steel die with the help

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of a ram or plunger.

10. What are the disadvantages of forging processes? (Dec. 2009)

Complicated shapes cannot be produced.
Generally used for large parts.
Because of cost of dies, process is costly.

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.

2. What is super plastic forming operation?

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.

3. What is press brake?

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.

4. Define hydro forming process.

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Hydro forming is a process which can be carried out in two ways:

Hydro - mechanical forming: In this method , the blank is placed over the punch whose

shape is similar to inner of the find workpiece.

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.

5. Give the difference between punching and blanking.

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.

6. How is hydro forming is similar to rubber forming ?

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.

7. What do you mean by minimum bend radius?

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.

8. Define limiting drawing ratio.

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.

2. List out the material for processing of plastics?

The following mentioned are the various polymer additives used in practice:

(1) Filler material (2) Plasticizers (3) Stabilizers

(4) Colorants (5) Flame retardants (6) Reinforcements

(7) Lubricants.

3. List the advantage of cold forming of plastics? (MAY 2007)

ADVANTAGES:
Cold forming can be carried out at room temperature
It is used to produce filament and fibres
It is a simple process.

4. What is film blowing? (May 2007)

In this process a heated doughy paste of plastic compound is passed through a

seriesof hot rollers, where it is squeezed into the from of thin sheet of uniform thickness.
It isused for making plastic sheets and films.

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5. What are the types of plastics ? (May 2008)

Polymers are classified in two major categories:

Thermoplastic polymers (Soften when heated and harden when cooled)

Thermosetting polymers (Soften when heated and permanently hardened when cooled)

6. What is compression moulding? (May 2008)

The main objective is to melt the material due to compression.

7. Name the parts made by rotational moulding. (Dec. 2008)

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.

8. What is parison ? (Dec.2008)

Blow moulding consists of extrusion of the heated tubular plastic piece called asparison
which is transferred to the two piece mold.

9. Define degree of polyenerization. (Dec. 2009)

It is the number of repetitive units present in one molecule of a polymer.

=

10. What is rotational mouldig of plastics? (Dec. 2009)

Rotataionalmoulding also called asroto-moulding.
A measured amount of polyemer power is placed in a thin walled metal mould
andthe mould is closed.
Then the mould is rotated about two mutually perpendicular axes as it is heated

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