A Course File

On

Manufacturing process
(II- B. Tech. – II– Semester)

Submitted to
DEPARTMENT OF MECHANICAL ENGINEERING

By

SHANKARLINGA.B.S
(Asst. Professor, Dept. of ME)

CMR ENGINEERING COLLEGE

Kandlakoya(V), Medchal Road, Hyderabad – 501 401
Ph. No. 08418-222042, 22106 Fax No. 08418-222106

(2017-18)
 CONTENTS

Sl. No. Particulars Page No.

1 JNTUH Syllabus
2 Student Entry Behavior or Pre-requisites
3 Course Objectives
4 Course Outcomes
5 Mapping of Course with PEOs-PSOs-POs
6 Mapping Of Course Outcomes with PEOs
7 Mapping Of Course Outcomes with PSOs
8 Mapping Of Course Outcomes with POs
9 Direct Course Assessment
10 Indirect Course Assessment
11 Overall Course Assessment and Attainment level
Pi diagrams, Bar charts, Histograms for representing
12
results
13 Lesson/Course Plan
14 Actions and Assessment Plan
15 Lecturer Notes
16 Question Bank
17 Internal Examination Question Papers with key
18 External/End Examination Question Papers
 SYLLABUS
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY
HYDERABAD
II Year B.Tech. L T/P/D C 2 -/-/3 4

PRODUCTION TECHNOLOGY

UNIT – I
CASTING: Steps involved in making a casting – its applications. – Patterns and Types of
patterns – pattern allowances and their construction. Types of casting processes Solidification
of casting.

UNIT – II
Welding: Welding types - Oxy – Acetylene Gas cutting- standard time and cost calculations.
ARC welding, Forge welding - resistance welding, Thermit welding

UNIT – III
Inert Gas welding, TIG & MIG welding, Friction welding, Induction welding, Explosive
welding, Laser welding, Soldering & Brazing. Heat affected zones in welding.
Welding defects – causes and remedies – destructive non-destructive testing of welds.

UNIT – IV
Hot working, cold working, strain hardening, recovery, recrystallisation and grain growth,
Comparison of properties of Cold and Hot worked parts, rolling fundamentals – theory of
rolling, types of Rolling mills and products. Forces in rolling and power requirements.
Stamping, forming and other cold working processes : Blanking and piercing – Bending and
forming – Drawing and its types – wire drawing and Tube drawing – coining – Hot and cold
spinning – Types of presses and press tools. Forces and power requirement for the above
operations.

UNIT –V
EXTRUSION OF METALS: Basic extrusion process and its characteristics. Hot extrusion
and cold extrusion - Forward extrusion and backward extrusion – Impact extrusion–
Extruding equipment – Tube extrusion and pipe making. Hydrostatic extrusion. Forces in
extrusion
Forging processes: Forging operations and Principles – Tools – Forging methods – Smith
forging, Drop Forging – Roll forging – Forging hammers: Rotary forging – forging defects
– cold Forging, swaging, Forces in Forging operations

TEXT BOOKS :

1. Manufacturing Technology (Vol.1)/ P.N. Rao/TMH/ 2nd Edition

2. Workshop Technology(Vol.1)/ Hajra Chowdary/Asia Publishing House/ 2nd Edition

REFERENCES:
1. Production Technology /Sarma P C / S.Chand
2. Production Technology / R.K. Jain
2. Metal casting / T.V Ramana Rao/New Age
3. Principles of Metal Castings / Roenthal /TMH
4. Production Engineering – Suresh Dalela & Ravi Shankar / Galgotia Publications Pvt. Ltd.
For more details, visit http://www.jntu.ac.in/
 2. Student Entry Behavior or Pre-requisites

1. Skills which the student already possesses those are relevant to the learning task.

2. Manufacturing processes related to machining are included in this subject.

3. All machines are included in this course to understand the basic concepts in machining science
 3. Course Objectives

Course Course Objective Statements

Objectives

Employ fundamental techniques to manufacture an engineering

Objective - 1
component.

Manufacture engineering components through foundry, metal forming,

Objective – 2
welding, non-conventional machining and powder metallurgy techniques.

Investigate and develop a methodology and establish a manufacturing

Objective – 3
sequence to fabricate engineering components.

Find the probable routes to manufacture a particular engineering

Objective – 4
component.

Selected the most economical route to fabricate the required engineering

Objective – 5
component

To have a substantial idea in topics which are advanced in manufacturing

Objective - 6
process.

4. Course Outcomes

Course Course Outcome Statements

Outcome

The ability to apply current knowledge and adapt to emerging applications

CO - 1
of mathematics, science, engineering and technology.

Successful completion of a comprehensive design project that

demonstrates the ability to improve the manufacturability of product
CO – 2
designs and design effective new manufacturing/assembly processes and
procedures.

Meaningful work experience in the manufacturing engineering technology

CO – 3
field.

CO – 4 The ability to apply project management techniques to the completion of

lab assignments and projects.
The ability to articulate the economic and organizational importance of
CO – 5
manufacturing to companies, individuals and the community.

Competence in the use of the computer as a problem solving and

CO - 6
communications tool.
 Course Objective and Course Outcome Mapping (only Ticking)

Outcome
CO1 CO2 CO3 CO4 CO5 CO6
Objective

Objective - 1 √

Objective – 2 √

Objective – 3 √

Objective – 4 √

Objective – 5 √

Objective - 6 √
 5. Mapping of Course with PEOs-PSOs-POs

Sl. No. PEOs Name Program Education Objective Statements

1 PEO – 1 Enrich fundamental knowledge in mathematical, science,

engineering concepts with core competency in diversified
fields to analyze and solve the mathematical problems.[PO’s:
1,2,3,4,5,6,7,8,9,10,11 and 12] [PSO’s: 1,2,3]

2 PEO – 2 Inculcate design & analysis skills on par with technological

changes in core and allied domains for result of higher
education &research, careers and entrepreneurship. [PO’s:
1,2,3,4,5,6,7,8,9,10 ,11and 12] [PSO’s: 1, 2 and 3]

3 PEO – 3 Infuse life-long learning, professional ethics, responsibilities

along with ability to communicate effectively to adapt to
innovation and change with a sense of social and
environmental concern. [PO’s: 1,2,3,4,5,6,7,8,9,10,11 and 12]
[PSO’s: 2 and 3]

Program Specific Objectives (PSOs)

Sl. No. PSOs Name Program Specific Objective Statements

1 PSO – 1 Apply fundamental of mathematics, basic science and

engineering by using state of art technologies to solve the
problems related to thermal and production fields.
[PO:1,2,3,4 and 5] & [PEO:1 and 2]

2 PSO – 2 Implement profound knowledge of engineering to model,

design, analyze the mathematical components &systems using
design tools such as CATIA, ProE , ANSYS, ABAQUS, For
future research and career advancement. [PO:1,2,3,4,5,10
11and 12]& [PEO:1,2 and 3]

3 PSO – 3 Ensure employability and career development skills through

Industry oriented mini & major projects, internship,
industry visits, seminars and workshops. [PO:6,7,8,9,10,11
and 12] & [PEO:1,2 and 3]
 Program Outcomes (POs)

PO Graduate PO Statements
Name Attributes

PO1 Engineering Apply the knowledge of mathematics, science, engineering fundamentals, and an
knowledge engineering specialization to the solution of complex engineering problems. [PEO’s:
1,2 and 3] [PSO’s: 1,2 and 3]

PO 2 Problem analysis Identify, formulate, review research literature, and analyze complex engineering
problems reaching substantiated conclusions using first principles of mathematics,
natural sciences, and engineering sciences. [PEO’s: 1,2 and 3] [PSO’s: 1,2 and 3]

PO 3 Design/ Design solutions for complex engineering problems and design system components or
development of processes that meet the specified needs with appropriate consideration for the public
solutions health and safety, and the cultural, societal, and environmental considerations.
[PEO’s: 1,2 and 3] [PSO’s: 1,2 and 3]

PO 4 Conduct Use research-based knowledge and research methods including design of experiments,
investigations of analysis and interpretation of data, and synthesis of the information to provide valid
complex problems conclusions. [PEO’s: 1,2 and 3] [PSO’s: 1,2 and 3]

PO 5 Modern tool usage Create, select, and apply appropriate techniques, resources, and modern engineering
and IT tools including prediction and modeling to complex engineering activities with
an understanding of the limitations. [PEO’s: 1,2 and 3] [PSO’s: 1,2 and 3]

PO 6 The engineer and Apply reasoning informed by the contextual knowledge to assess societal, health,
society safety, legal and cultural issues and the consequent responsibilities relevant to the
professional engineering practice. [PEO’s: 2 and 3]

PO 7 Environment and Understand the impact of the professional engineering solutions in societal and
sustainability environmental contexts, and demonstrate the knowledge of, and need for sustainable
development. [PEO’s: 1,2 and 3]

PO 8 Ethics Apply ethical principles and commit to professional ethics and responsibilities and
norms of the engineering practice. [PEO’s: 1,2 and 3] [PSO’s: 2 and 3]

PO 9 Individual and Function effectively as an individual, and as a member or leader in diverse teams, and
team work in multidisciplinary settings. [PEO’s: 1,2 and 3] [PSO’s: 3]

PO 10 Communication Communicate effectively on complex engineering activities with the engineering

community and with society at large, such as, being able to comprehend and write
effective reports and design documentation, make effective presentations, and give
and receive clear instructions. [PEO’s: 1,2 and 3] [PSO’s: 2 and 3]

PO 11 Project Demonstrate knowledge and understanding of the engineering and management

management and principles and apply these to one’s own work, as a member and leader in a team, to
finance manage projects and in multidisciplinary environments. [PEO’s: 1 and 3] [PSO’s: 2
and 3]

PO 12 Life-long learning Recognize the need for, and have the preparation and ability to engage in independent
and life-long learning in the broadest context of technological change. [PEO’s: 1,2 and
3] [PSO’s: 1,2 and 3]
 Course Mapping

Course Name PEO1 PEO2 PEO3 PSO4 PSO5 PSO6

PRODUCTION
TECHNOLOGY √ √ √ √ √ √

Course Name Po1 Po2 Po3 Po4 Po5 Po6 Po7 Po8 Po9 Po10 Po11 Po12

PRODUCTION
TECHNOLOGY √ √ √ √ √ √ √ √ √ √ √ √
 6. Mapping Of Course Outcomes With PEOs

No Course Outcomes PEO1 PEO2 PEO3

CO – 1 √ √ √
1
√ √ √
2 CO – 2

√ √ √
3 CO – 3

√ √ √
4 CO – 4

√ √ √
5 CO – 5

√ √ √
6 CO – 6

No Course Outcomes PSO1 PSO2 PSO3

1 CO - 1 3 2 1

2 CO – 2 2 2 2

3 CO – 3 3 3 3

4 CO – 4 3 3 2

5 CO – 5 2 3 3

6 CO - 6 3 3 2
 7. eMapping Of Course Outcomes With PSOs

No Course Outcomes PSO1 PSO2 PSO3

CO - 1 √ √ √
1
√ √ √
2 CO – 2

√ √ √
3 CO – 3

√ √ √
4 CO – 4

√ √ √
5 CO – 5

√ √ √
6 CO - 6

No Course Outcomes PSO1 PSO2 PSO3

1 CO - 1 3 2 3

2 CO – 2 3 2 3

3 CO – 3 3 2 3

4 CO – 4 1 3 3

5 CO – 5 2 2 3

6 CO - 6 3 1 3
 8. Mapping Of Course Outcomes With POs

No Course Outcomes Po1 Po2 Po3 Po4 Po5 Po6 Po7 Po8 Po9 Po10 Po11 Po12

1 CO - 1 √ √ √ √ √ √ √ √ - √ √ √

2 CO – 2 √ √ √ √ √ √ √ √ - √ √ √

3 CO – 3 √ √ √ √ √ √ √ √ √ √ √ √

4 CO – 4 √ √ √ √ √ √ √ √ √ √ √ √

5 CO – 5 √ √ √ √ √ √ √ √ √ √ √ √

6 CO - 6 √ √ √ √ √ √ √ √ √ √ √ √

Course Po Po
No Po1 Po2 Po3 Po4 Po5 Po7 Po8 Po10 Po11 Po12
Outcomes 6 9

1 CO - 1 3 3 3 3 3 3 2 2 2 2 3 3

2 CO – 2 3 3 3 3 2 3 2 2 3 2 3 3

3 CO – 3 3 3 3 3 2 3 2 2 3 2 3 3

4 CO – 4 3 3 3 3 2 3 2 2 3 2 3 3

5 CO – 5 3 3 3 2 2 3 2 2 3 2 3 3

6 CO - 6 3 3 3 3 2 3 2 2 2 2 3 3
 9. Direct Course Assessment
I Direct Assessment Through Tests is(Internal+External) is for 80%
Weightage:
Tools Used: Internal Exams, External Exams, Clearing Subject &
Assignments:
Targeted Actual
No Description Remarks Course Attainment
Performance Performance
65% of All Course the
Students(94 Outcomes in general
94 Students
Internal Students) should attained & Marks
1
Marks(25)
Secured 16 Awarded or
2.5M
Secure 65% of
Marks Attainment Level is
Internal Marks
3(Strong & High)
i.e., 16Marks
55% of 35Students All the Course
Students(35 Secured 41 Outcomes in general
External Students) should Marks attained & Marks
2
Marks(75) Awarded or
1.4M
Secure 55% of
External Marks Attainment Level is
3(Strong & High)
i.e., 41 Marks
95 Students
A minimum of should
All the Course
Clearing of 70% of secure 91 Outcomes in general
Subject or Students(91 Marks or 3 attained & Marks
3 3M
acquiring credit Students) should Awarded or
as mentioned
Credits Attainment Level is
clear this course whichever 3(Strong & High)
in first attempt
is lower

60% of Students All Course

120Students Outcomes in general
should secure
out of 130 attained Marks
4 Assignments 60% of Awarded or
3M
students got
Assignment Attainment Level is
5 Marks
Marks i.e., 5M.. 3(Strong & High)
Average Course Attainment=(2.5+1.4+3+3)/4=(9.9/4)=2.4 High
 Course Attainment Level=3M(High)
 Performance in Internal & End Exams is Substantial.
 Hence all the Course Outcomes are summarily Attained
 As Direct Assessment is equal to 80% of 2.4 Marks i.e., 2 Marks
 10. Indirect Course Assessment

Mission Statement of ME
 Provide fundamentals and state of art technical knowledge to promote quality
education in frontier areas of Mechanical Engineering.
 Emphasize on collaborative research and consultancy by initiating MOUs with
industries and R&D organizations.
 Enrich the abilities of self learning, ethics, entrepreneurship and leadership
through effective interaction with stakeholders to handle real world challenges.

Category: Faculty/GB Members/Eminent Academicians/ Industrialists/Professional

Association Members/Alumni Association/ Resource Persons of Guest Lectures,
Seminars, Workshops, FDPs, Fests, Conferences.
Representing Person Name & Address:_________________ & Category:________

No Mission Elements Strong Moderate Weak No

Comment
M-1 Fundamentals 9*3 1*2 0*1 2.9

M-2 Technical Knowledge 8*3 2*2 0*1 2.8

M-3 Quality Education 10*3 0*2 0*1 3

M-4 Emphasize On Collaborative Research 0*3 0*2 10*1 1

M-5 Enrich Self Learning Abilities 6*3 4*2 0*1 2.6

M-6 Ethics, Entrepreneurship And Leadership 1*3 9*2 0*1 2.1

Ability

M-7 Effective Interaction With Stakeholders 0*3 0*2 10*1 1

M-8 Real World Challenges 0*3 0*2 10*1 1

Total 16.4

Percentage 2.05
 Course Assessment through Student Satisfaction Survey
(Using Indirect Assessment Technique through a feedback for a Weightage of 20%)
Year & Semester: 2&1 Academic
Year:2014-15
Course Title: Production Technology
No. of Students on Rolls as per Attendance Register: 130 (Response by:
126)
Name of the Faculty: Mr. Satya Prakash Ganti Designation:
Assoc.Prof.
Mo No
Question Based Stron dera Wea co
Gra
on Mission Medium/Pa g/ te/ k/ m
No Total de
PEO/PO/PSO/C Element rameter high med low me
%
O (3) ium (1) nt
(2) (0)
Class room
teaching,
simulations
, labs,
practice,
mini &
main
To what extent
Provide Projects,
the course
fundamental conferences
provide
s and state of ,
fundamentals
art professiona 30* 10*
1 knowledge with 90*3 340 2.69
technology to l and 2 1
state of art
promote student
technology to
quality association
promote quality
education activities,
education?
technical
clubs, guest
lectures,
workshops,
student
technical
fests
simulations
, labs,
practice,
mini &
main
Projects,
conferences
To what extent
Emphasize , prof. and
the course
on student 25* 10*
2 emphasize on 95*3 345 2.73
collaborative association 2 1
collaborative
research activities,
research?
technical
clubs, guest
lectures,
workshops,
student
technical
fests
3 Does the course Interaction Class room 60*3 50* 20* 300 2.38
have any scope teaching, 2 1
for interaction simulations
with , labs,
stakeholders practice,
mini &
main
Projects,
conferences
 , prof. and
student
association
activities,
technical
clubs, guest
lectures,
workshops,
student
technical
fests
NSS
Activities,
Rate focus of
Environme
the course
ntal Events,
towards Professional
Literary
addressing ethics, 45* 15*
4 events/activ 70*3 315 2.5
professional & with realistic 2 1
ities,
ethical issues problems
professiona
w.r.t. realistic
l
problems
association
activities
Rate the role of
TLP, use &
the facilitator in
availability
mentoring and Continuous of digital
promoting the
self learning library, 20* 20*
5 self learning 90*3 330 2.61
ability internet 2 1
abilities to excel
access,
academically
industrial
and
visits
professionally?
Rate the Tools,
methodology techniques,
adopted and methods,
40* 20*
6 techniques used TLP teaching 70*3 310 2.46
2 1
in teaching aids used in
learning class room
processes. instructions
Rate the course
in applying
Mini and
sciences &
Applying main
engineering
fundamental projects,
fundamentals in 40* 20*
7 s & use of latest 70*3 310 2.46
providing 2 1
modern tools software,
research based
for R&D and R&D
conclusions with
activities
the help of
modern tools?
Main
Did the course
Design, Projects,
have any scope
develop and seminars,
to design, 100* 20* 10*
8 test a system workshops, 360 2.85
develop and test 3 2 1
or training
a system or
component programme
component?
s
9 Rate scope of Cultural, NSS 40*3 50* 40* 260 2.06
this course in legal, health, Activities, 2 1
addressing environment Environme
cultural, legal, and safety ntal Events,
health, issues Literary
environment events/activ
and safety ities,
issues? professiona
l
association
 activities
Group
projects,
Team
Events,
Scope of
simulations
applying use of
, practice,
management management
conferences
fundamentals to fundamental
, prof. and
demonstrate s for effective 40* 30*
10 student 60*3 290 2.30
effective project 2 1
association
technical management
activities,
project & control
technical
presentations & techniques
clubs,
report writing?
workshops,
student
technical
fests
Grand Average 2.50
 11. Overall Course Assessment

(80% Direct + 20% Indirect, if any)

No Assessment Type Weightage Attainment Level

Direct-Assignment, Quiz,
1 Subjective, University Exams, 0.80 0.80(2.4)=2 Max
Results, Bench Marks
Indirect-Surveys- 0.20(2.50)=0.5
2 0.20
Questionnaire Max
Overall 1.00 2.50 High

12. Pi diagrams, Bar charts, Histograms

 13.Lesson/Course Plan

Subject : PRODUCTION TECHNOLOGY

Year : II B.Tech
Branch :ME
Semester: II

S.NO NO. of DATE DATE TOPICS

hrs
FROM TO

1 10 hrs 14/12/17 23/12/17 UNIT ONE: : CASTING: Steps involved in making

a casting – Advantage of casting and its applications. –
Patterns and Pattern making – Types of patterns –
Materials used for patterns, pattern allowances and
their construction, Principles of Gating, Gating ratio
and design of Gating systems.

2 10 hrs 27/12/17 04/01/18 Solidification of casting – Concept – Solidification of

pure metal and alloys, short & long freezing range
alloys.
Risers – Types function and design, casting design
considerations, special casting processes 1) Centrifugal
2) Die, 3) Investment.
Methods of Melting: Crucible melting and cupola
operation, steel making processes, special.

3 08 hrs 06/01/18 27/1/18 UNIT II: : Classification of welding process types of

welds and welded joints and their
characteristics, design of welded joints, Gas welding,
ARC welding, Forge welding, resistance
welding, Thermit welding and Plasma (Air and water )
welding.
B) Cutting of Metals: Oxy – Acetylene Gas cutting,
water plasma. Cutting of ferrous, non-ferrous metals.

4 06 hrs 29/01/18 12/02/18 UNIT III: : Inert Gas welding, TIG & MIG, welding,
Friction welding, Induction welding, Explosive
welding, Laser
welding, Soldering & Brazing. Heat affected zones in
welding;
welding defects – causes and remedies – destructive
nondestructive testing of welds.

5 11 hrs 13/02/18 09/03/18 UNIT IV : : Hot working, cold working, strain

hardening, recovery, recrystallization and grain growth,
Comparison of
properties of Cold and Hot worked parts, Rolling
fundamentals – theory of rolling, types of Rolling mills
 and
products. Forces in rolling and power requirements.

6 10 hrs 10/03/18 22/03/18 Stamping, forming and other cold working processes :
Blanking and piercing – Bending and forming –
Drawing and its types – wire drawing and Tube
drawing – coining – Hot and cold spinning – Types of
presses and press tools. Forces and power requirement
in the above operations

7 10 hrs 23/03/18 07/04/18 UNIT V: : EXTRUSION OF METALS: Basic

extrusion process and its characteristics. Hot extrusion
and cold
extrusion - Forward extrusion and backward extrusion
– Impact extrusion Hydrostatic extrusion.
Forging processes: Principles of forging – Tools and
dies – Types Forging – Smith forging, Drop Forging
– Roll forging – Forging hammers: Rotary forging –
forging defects.
 14. Actions and Assessment Plan

Action & Assessment plan (to improve the course plan to meet the objectives)

Actions

Students should have to attend the lecture classes and maintain and follow the lecture notes
of the subject. There are other requirements other than attending the classes. The following
actions taken to improve the course plan and to meet the objectives.

1. Assignments

Assignments were given to students on weekly basis. Every week one topic will be given
based on previous year question papers and important topics from each topic as and when
then topic is thought to the students. Students’ evaluation will be done on the basis of
performance in the assignments and feedback will be given to improve their performance.

Mini Project

Students will be made to undergo a Mini Project for duration of 15 days along with their
class work. The project enables the students to be aware of machining processes.

2. Workshop & Seminars

Students are encouraged to attend various workshops held at different organizations in order
to improve their knowledge in machine tools subject. Seminars are conducted every
fortnightly at college premises and students take active participation in seminars on machine
tools
 15.Lecturer Notes

(Strictly add the notes unit wise with topic wise as per jntuh syllabus along with extra
or beyond syllabus topics, if any)
 16. Question Bank

MANUFACTURING PROCESS

I-METAL CASTING PROCESSES

1. Name any four types of commonly used patterns

2. What is the merit of CO2 process?

3. State the essential properties of mounding sand

4. Give any two merits and demerits of investment casting process

5. Mention any two merits and demerits of die casting

6. List out any four defects in casting

7. What is meant by split pattern

8. Define the term mould

9. What are the defects caused by low pouring temperature?

10. What is meant by match plate pattern making?

11. How will you calculate grain fineness number?

12. How patterns differ from casting?

13. What are the tests carried out to determine the quality of casting?

14. What are the functions of riser?

15. What are core prints?

16. What are the functions of gating and risering?

17. What is the composition of moulding sand?

18. What is the function of core?

19. Which process is called “Lost wax process”? Why?

PART-B

1. Discuss the properties of moulding sand.

2. What are the various moulding methods, explain them.

3. Explain the working principle of investment casting.

4. Discuss the casting defects and their inspection methods.

5. What are the pattern making allowances and briefly explain them.

6. Describe centrifugal casting process.

7. Describe the shell moulding process.

8. Explain the ceramic moulding process and state its merits and demerits.

9. What are the factors which govern the selection of a proper material for pattern
making?

10. What are the specific advantages of match plate patterns? Explain how they are used
for making mould.

11. Classify the types of patterns and sketch any three of them.

12. What is core and explain how to make a core?

13. Explain the construction and operation of Cupola furnace with diagram.

14. Write a short note on “Chills”

15. Describe various materials used for making patterns. What are its merits and
demerits.

16. What are the basic requirements of core sand? How does it differ from the moulding
sand?

17. What are the different types of furnace used in foundry? Describe in detail with neat
sketches any one of them.

18. Describe the steps involved in the preparation of green sand mould with cope and
drag pattern.

19. Briefly explain cold-chamber die casting process with a neat sketch.

20. What are the advantages of centrifugal casting?

II- WELDING PROCESSES

1. What is the principle of resistance welding?

2. What is the role of fluxes in welding? Or function of flux in welding?

3. List out any four arc welding equipment.

4. What is the principle of Thermit welding?

5. What are the different types of gas flames? How are they formed?

6. Differentiate soldering and brazing .

7. What is the chemical reaction occurs in thermit welding?

8. What are the advantages of carbon arc welding?

9. Differentiate between oxy-acetylene and air-acetylene welding

10. What are the advantages of a.c. arc welding?

11. What is the principle cause of cracks in weld metals?

12. How do you specify an electrode?

13. What is the function of shielding gas in welding?

14. Why laser welding is used only for micro-welding applications?

15. Define resistance welding

16. What is flux? Why is it essential to use it in some welding situations?

17. What are the defects that are generally found in welding?

18. List any four applications of TIG Welding process.

19. Is flux necessary in Brazing process? If yes why?

20. How inclusions in welding slag is avoided?

PART-B

1. Distinguish between gas and arc welding

2. What are the advantages of welding?

3. Explain percussion welding

4. Describe Electro slag welding

5. Distinguish between soldering and brazing

6. Explain spot welding

7. Explain submerged are welding

8. Explain the electron beam welding process with a neat sketch

9. Write a brief note on “Welding defects”

10. Sketch the three types of Oxy-acetylene flames and state their characteristics and
applications.

11. Describe the electro-slag welding process with a neat sketch.

12. What is the principle of resistance welding and explain the seam welding?

13. Describe plasma arc welding

14. What are the different types of electrode? What are the functions of flux coating?

15. What is the principle of friction welding?

16. Describe metal inert Gas arc welding process with a neat sketch.

17. Briefly explain on butt welding process

18. Give a brief account of classification of welding processes?

19. Explain TIG welding process variables and enumerate its advantages
20. Describe shielded metal arc welding process with suitable diagram. What are its
applications?

21. What is the difference between welding, brazing and soldering process?

III-BULK DEFORMATION PROCESSES

1. List out the types of forging machines

2. What are the types of rolling mills?

3. What are the four major draw backs of hot working?

4. Classify the types of extrusion

5. State any two effects produced by Cold-working

6. What are the two basic types of forging process?

7. What do you understand by forging? What are the advantages?

8. List out the forging defects

9. Classify the types of forging machines

10. State the defects in rolled parts.

11. What are the advantages of cold forming?

12. What is the purpose of piercing operation?

13. Name any four limitations of hot forging

14. Write the limitations of hot working process

15. What is the difference between stretch forming and bending?

16. What do you understand by recrystallisation and recrystallisation temperature?

17. What are the general advantages of forging as a manufacturing process?

18. List the functions of Back-up rollers in rolling operation?

19. Discuss in brief open die and closed die forging

20. What is the principle of impact forging?

PART-B

1. Classify the types of forging machines and explain any one

2. Explain the forward and back extrusion process

3. Classify the types of rolling mills and sketch them

4. List out various forging defects

5. Describe hydrostatic extrusion process.

6. Compare press forging and hammer forging

7. Explain the tube piercing process

8. Distinguish hot and cold extrusion process and briefly explain one in each.

9. Describe the principle of rolling. Write the various kinds of rolling mills along with
their applications

10. What are the types of power hammers available and explain the pneumatic hammer
with a neat sketch

11. Describe the difference between a bloom, a slab and a billet. Explain the features of
different types of rolling process.

12. Discuss the effects of temperature, strain rate and friction on metal forming process

13. Explain with a sketch, what is meant by flat strip rolling.

14. Explain the procedure for making the head of Bolt by forging operation

15. Name the hand forging operation and explain briefly about them.

16. Explain with a neat sketch of roll forging process.

17. Describe the following processes

18. Roll die forging b. Skew rolling c. Ring rolling

IV- SHEET METAL PROCESSES

1. What is blanking?

2. What is punching operation?

3. What are the different types of metals used in sheet metal work?

4. Mention any four products produced by spinning process?

5. In which member the clearance should be given for blanking and piercing?

6. What is the difference between stretch forming and bending?

7. List various operations generally performed in a sheet metal shop

8. Show the details of punching process with the help of a simple sketch

9. Give the difference between punching and blanking

10. List the various sheet metal that can be formed in press working

11. Define the term spring back

12. What are the advantages of stretch forming operation?

13. What are the types of special forming processes?

14. What are the advantages of hydro forming process?

15. State the limitations and applications of rubber pad forming process

16. What is metal spinning process?

17. State the advantages and applications of explosive forming process

18. What is peen forming process?

19. What are the advantages and disadvantages of peen forming process

20. What are the applications of super plastic forming process?

V FORGING AND EXTRUSTION PROCESSES

1. Explain any one stretch forming operation

2. Define formability and how it is tested?

3. What is drawing operation?

4. Explain the metal spinning operation

5. Describe the magnetic pulse forming process

6. What is deep drawing operation? Explain with a neat sketch.

7. Explain rubber pad forming process

8. Describe the electro hydraulic forming process

9. Describe the explosive forming process

10. How are aluminium kitchen utensils produced?

11. Describe the process of hydro forming

12. Describe the various methods of rubber forming. Where are these processes used?

13. What is super plastic forming?

14. Describe the hydro forming process with the help of neat diagram

15. Explain the characteristic features of sheet metal used in forming process

16. Explain peen forming process

 17.Internal Examination Question Papers

(Includes solutions/reference pages of notes for subjective and keys for objective
papers)

CMR ENGINEERING COLLEGE

Kandlakoya (v), Medchal Road, Hyderabad -501401
II B.TECH II-SEM I MID EXAM Marks: 20 M
Subject: MP Branch: MECH Time: 1hr

Answer any TWO questions 2*5= 10Marks

1. Explain the steps involved in casting?

2. Name the allowances that are given on a pattern? Describe them in brief?
3. Explain in Brief, (i) Centrifugal Casting, (ii) Die Casting, (iii) Investment Casting,
(iv) Shell Casting?
4. What are 3 methods of riser design and explain them with derivations?
5. Explain following Different Welding processes (i) Arc Welding, (ii) Forge Welding,
(iii) Submerged Welding?

CMR ENGINEERING COLLEGE

Kandlakoya (v), Medchal Road, Hyderabad -501401
II B.TECH II-SEM II MID EXAM Marks: 20 M
Subject: MP Branch: MECH Time: 1hr

Answer any TWO questions 2*5= 10Marks

1. List out the difference between Destructive & Non Destructive testing’s & Explain
various Non Destructive testing’s?
2. What is Rolling? Explain the different types of rolling processes based on No. of rolls
on stand?
3. A 50 mm thick alluminium alloy strip is rolled to a thickness of 4mm using steel rolls
of radius 100 mm. The tensile yield stress of alluminium is 0.28 KN/mm2. Assuming
rolling speed of 95 rpm. The width of strip is 200mm. Determine: a) Co-efficient of
friction, b) Angle subtended by contact zones, c) Rolling force, d) Power required for
rolling operation.
4. What is forging operation? Classify the different forging operations
 18.External/End Examination Question Papers

(Previous papers of either JNTUH or other University or Gate or competitive

Examinations, if any)
Code No: R05310303 Set No. 1
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, HYDERABAD
B.Tech II Year - II Semester Examinations, April-May, 2007
PRODUCTION TECHNOLOGY
(Common to AME, ME, MCT)
Time: 3 hours Max. Marks: 80
Answer any five questions
All questions carry equal marks
1 (a) What are composite moulds? Why are they used? Where are they used?
(b) What are different types of gates in sand moulding process? [9+7]

2. (a) Sketch a graph of specific volume Vs Temperature for a metal that shrinks as it
cools from the liquid state to room temperature. On graph, mark the area where
shrinkage is compensated for by risers?
(b) What is the difference between the solidification of pure metals and metal
alloys? Explain. [8+8]

3. (a) Why is it possible for fusion zone to have a chemistry that is different from that of
the filler metal? Explain.
(b) Sketch and explain various welding positions? Give their applications [8+8]

4. (a) What are the disadvantages of bare wire electrode as filler metal.
(b) Mention the causes and remedies for magnetic arc blow. [8+8]

5. (a) Explain the possible defects in rolling and suggest suitable remedies.
(b) On a certain mill the rolling load for 25% reduction is 7KN/mm of width.
What is the rolling load when front and back tensions of 120 and 150MPU are
applied? σ0 = 13KN/mm2 and α = 2β. [8+8]

6. (a) Write short notes on elements of die and press.

(b) Explain the working of hydraulic press with neat sketch. [8+8]

7. (a) Distinguish between forward extrusion and backward extrusion processes.

(b) What are the various forging hammers? Discuss their advantages and limita-
tions. [8+8]

8. With the help of suitable figures explain the blow moulding process. Mention its
applications and advantages. [16]

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Code No: R05310303 Set No.2

 JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, HYDERABAD
B.Tech II Year - II Semester Examinations, April-May, 2007
PRODUCTION TECHNOLOGY
(Common to AME, ME, MCT)
Time: 3 hours Max. Marks: 80
Answer any five questions
All questions carry equal marks

1 (a) Why is match plate pattern is much easier to use than a standard pattern? Explain.
(b) What are the undesirable effects that could result from turbulence of the metal
in the gating system and mould cavity? Explain. [8+8]

2. (a) Is there any difference in the tendency for shrinkage void formation for metals with
short and long freezing ranges, respectively? Explain.
(b) Make a list of safety considerations and precautions that should be taken
concerning all aspects of melting and casting of metals, including equipment
involved? [8+8]

3. (a) Explain the effect of polarity on penetration in DC arc welding with a neat sketch?
(b) Explain the principle of arc welding with all the elements in the circuit. [8+8]
4. (a) What are the characteristics of heat affected zone in welding?
(b) Describe the difference between brazing and soldering?
(c) Describe with the help of a neat sketch the principle of spot welding. [5+5+6]
5. (a) Explain the effect of rolling variables on rolling load and rolling process.
(b) Describe classification of rolling process and mills. [8+8]

6. (a) What is coining? Explain the process with the help of a neat sketch.
(b) Explain the mechanism of blanking and what are the different stages of blank-
ing? [8+8]

7. (a) What is the difference between open die forging and impression die forging?
(b) What are the attractive features of extrusion process? [8+8]

8. (a) Distinguish between thermosetting plastics and thermoplastics. Give their

applications.
(b) List few components manufactured by the injection moulding and justify why
they are manufactured by this process. [8+8]

⋆⋆⋆⋆⋆
Code No: R05310303 Set No.3
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, HYDERABAD
B.Tech II Year - II Semester Examinations, April-May, 2007
PRODUCTION TECHNOLOGY
(Common to AME, ME, MCT)
Time: 3 hours Max. Marks: 80
Answer any five questions
All questions carry equal marks
1 (a) What are the advantages of casting process over other production processes?
(b) Give advantages of different pattern materials? [8+8]

2. (a) Sketch and explain the construction and operation of hot chamber die casting process.
(b) What are different zones in cupola? Explain. [8+8]

3. (a) Explain the plasma arc cutting process with neat sketch.
(b) Explain fusion as it relates to welding operation? [8+8]
4. (a) Explain with neat sketch the forge welding process?
(b) Describe the types of fluxes used in soldering and their applications? [8+8]

5. (a) What is the significance of recrystallization temperature in metal working Explain?

(b) Sketch common types of rolling mills and briefly state the applications of each.
[8+8]

6. (a) Describe how hot working can be used to improve the grain structure of a metal.
(b) Why is lubrication often a major concern in metal forming? Explain. [8+8]

7. (a) What principles are normally considered good practice in the design of drop forgings?
(b) How are tubes extruded? Explain with a sketch. [8+8]

8. (a) Why are the fabrication process applied to plastics often different from those applied to
metals? What are the reasons. Explain.
(b) What are some of the ways that plastic sheet, plate and tubing can be cast?
[8+8]

⋆⋆⋆⋆⋆
Code No: R05310303 Set No.4
JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, HYDERABAD
B.Tech II Year - II Semester Examinations, April-May, 2007
PRODUCTION TECHNOLOGY
(Common to AME, ME, MCT)
Time: 3 hours Max. Marks: 80
Answer any five questions
All questions carry equal marks
1. (a) Give an account of relative advantages and disadvantages of different pattern materials.
(b) What is the function of sprue well in gating system. [8+8]

2. (a) Explain various steps for making a casting by die casting process.
(b) What are the advantages and applications of die casting? [8+8]
3. (a) Describe the seam welding process with neat sketch?
(b) Write the applications, advantages and limitations of projection welding?
[8+8]

4. (a) Explain the effect of thermal conductivity and thermal expansion on welding process?
(b) Why are residual stresses important in welded components? Describe the
methods used for relieving or reducing residual stresses in welds? [8+8]
5. (a) Explain the methods of eliminating work hardening effect.
(b) How does the number of passes be estimated for rolling of a particular com-
ponent? [8+8]
6. (a) Distinguish between open frame and closed frame of presses.
(b) What are the various press tool components? [8+8]
7. (a) Distinguish between forward extrusion and backward extrusion processes.
(b) What are the various forging hammers? Discuss their advantages and limita-
tions. [8+8]

8. (a) What are the various components which make up a moulding compound for plastics and
explain the function of each?
(b) What are the advantages of the casting method of moulding plastic parts?
[8+8]

⋆⋆⋆⋆⋆