JAYA SAKTHI ENGINEERING COLLEGE

(ApprovedbyAICTE&Affiliated toAnnaUniversity,Chennai)
St. Mary’s Nagar Thiruninravur, Chennai- 602 024

Department of Mechanical Engineering

Question Bank
Year/Sem: II Year/III Sem
ME3393-Manufacturing Process

UNIT – I
METAL CASTING PROCESSES
Part – A (2 – Marks)
1. State any four types of pattern.
2. What are the causes for the formation of blow holes in the sand casting?
3. What is meant by core print? Write the applications of core print.
4. Name the different melting furnace employed for metal casting.
5. Compare the advantages of metal mould over sand (expandable) mould.
6. What are the function of flux in melting metal and alloys?
7. Differentiate Shrinkage and Porosity
8. Define casting. List the various sand casting defects
9. What is pattern?
10. What is meant by grain fineness number?
11. Mention few applications of centrifugal casting.
12. What factors are to be considered in calculating the shrinkage allowance?
13. What are the essential requirements of core sand?
14. What is the merit of CO2 process?
15. State the essential properties of mounding sand
16. Give any two merits and demerits of investment casting process
17. Define the term mould
18. What are the defects caused by low pouring temperature?
19. What is meant by match plate pattern making?
20. How will you calculate grain fineness number?
21. How patterns differ from casting?
22. What are the tests carried out to determine the quality of casting?
23. What are core prints?
24. What are the functions of gating and risering?
25. What is the composition of moulding sand?
26. What is the function of core?
27. Which process is called “Lost wax process”?Why?

Part – B (13 – Marks)

1. Explain the various steps involved in lost wax process with suitable sketches.
2. Write short notes on ceramic mould and centrifugal casting.
3. What are the allowances given while making pattern? Explain.
4. Describe the process of investment casting. What process controls are needed in this case?
5. Explain the principle and operation of CO2 moulding. Also write its merits and demerits.
6. Describe with a neat sketch of cold chamber die casting machine. give its advantages and limitations.
 7. Describe with a neat sketch of hot chamber die casting machine.
8. Enumerate some common defects of casting and explain the reasons which cause these defects.
9. Discuss the properties of moulding sand.
10. What are the various moulding methods, Explain them
11. Explain the working principle of investment casting
12. Discuss the casting defects and their inspection methods
13. What are the pattern making allowances and briefly explain them
14. Describe centrifugal casting process
15. Describe the shell moulding process
16. Explain the ceramic moulding process and state its merits and demerits
17. What are the factors which govern the selection of a proper material for pattern making?
18. What are the specific advantages of match plate patterns? Explain how they are used for making mould
19. Classify the types of patterns and sketch any three of them
20. What is core and explain how to make a core?
21. What are the advantages of centrifugal casting?

Part – C (15 – Marks)

1. Describe the stepwise procedure of making a mould with two piece split pattern.
2. Explain the properties required for moulding sand.
3. Explain the preparation of moulding sand process.
4. Explain any one type of centrifugal casting with neat diagram.
5. Explain the construction and operation of Cupola furnace with diagram
6. Write a short note on "Chills"
7. Describe various materials used for making patterns. What are its merits and demerits
8. What are the basic requirements of core sand? How does it differ from the moulding sand?
9. What are the different types of furnaces used in foundry? Describe in detail with neat sketches any one of them
10. Describe the steps involved in the preparation of green sand mould with cope and drag pattern
11. Briefly explain cold-chamber die casting process with a neat sketch.
 UNIT – II
JOINING PROCESSES
Part – A (2 – Marks)
1. What are the types of adhesives used in adhesive bonding?
2. What is meant by carburizing flame in gas welding?
3. What is the minimum distance maintained between two successive spot welding made by resistance
welding? Why?
4. Write short notes on transferred and non-transferred arc in plasma arc welding?
5. What is the purpose of flux in welding?
6. Sketch the different types of oxy-acetylene flame.
7. What is meant by nugget in electric resistance welding?
8. What are the functions of flux used in welding electrodes?
9. Name the various causes for the defect porosity in welding.
10. Write the difference between brazing and soldering.
11. What is spelter and give the composition of some commonly used spelters?
12. What is meant my autogeneous welding?
13. How the welding rod is designated?
14. List out types of welding defects.
15. What is the principle of resistance welding?
16. What is the role of fluxes in welding? Or function of flux in welding?
17. What is the principle of Thermit welding?
18. What are the different types of gas flames? How are they formed?
19. Differentiate soldering and brazing .
20. What is the chemical reaction occurs in thermit welding?
21. What are the advantages of carbon arc welding?
22. Differentiate between oxy-acetylene and air-acetylene welding
23. What are the advantages of a.c. arc welding?
24. What is the principle cause of cracks in weld metals?
25. How do you specify an electrode?
26. What is the function of shielding gas in welding?
27. Why laser welding is used only for micro-welding applications?
28. Define resistance welding
29. What is flux? Why is it essential to use it in some welding situations?
30. What are the defects that are generally found in welding?
31. List any four applications of TIG Welding process.
32. Is flux necessary in Brazing process? If yes why?
33. How slag inclusions in welding be avoided?

Part – B (13 – Marks)

1. Explain the principle of arc welding. What are the different weld positions in arc welding? Enumerate
some defects due to arc welding.
2. Explain the principle of resistance welding. What are the different types of resistance welding and
explain any one of them with neat sketch.
3. Explain various welding positions with neat sketch.
4. Explain the submerged arc welding process with neat diagram.
5. Explain the arc welding process with neat sketch.
6. Describe the ultrasonic welding process with neat diagram.
7. Explain in brief the function of various coating on a welding rod.
 8. Distinguish between gas and arc welding
9. What are the advantages of welding?
10. Explain percussion welding
11. Describe Electro slag welding
12. Distinguish between soldering and brazing
13. Explain spot welding
14. Explain submerged are welding
15. Explain the electron beam welding process with a neat sketch
16. Write a brief note on "Welding defects'
17. Sketch the three types of Oxy-acetylene flames and state their characteristics and applications.
18. Describe the electro-slag welding process with a neat sketch.
19. What is the principle of resistance welding and explain the seam welding?
20. Describe plasma arc welding
21. What are the different types of electrode? What are the functions of flux coating?

Part – C (15 – Marks)

1. Explain in detail the plasma arc welding process and write its application and demerits.
2. Explain with neat sketch the principle of resistance welding. Difference between upset welding and flash
welding.
3. Enumerate the various welding defects with causes of occurrence and describe a method of detecting crack
on a weld surface.
4. What is the principle of friction welding
5. Describe metal inert Gas arc welding process with a neat sketch.
6. Briefly explain on butt welding process
7. Give a brief account of classification of welding processes?
8. Explain TIG welding process variables and enumerate its advantages
9. Describe shielded metal arc welding process with suitable diagram.
10. What are its applications?
11. What is the difference between welding, brazing and soldering process?
 UNIT – III
METAL FORMING PROCESSES
Part – A (2 – Marks)
1. Define extrusion as manufacturing process. (May 2012)
2. Working on the metal lead at room temperature, is considered to be hot working. Why?
3. List the two advantages of cold extrusion over hot extrusion.
4. What is ironing?
5. What is meant by fullering?
6. What is the difference between hot and cold forging?
7. Differentiate extrusion and forging.
8. Define upsetting and drawing down in forging operation.
9. Sketch the different types of rolling mills.
10. Why is drop forging called so?
11. What does angle of bite in rolling mill?
12. What are the various forming process?
13. Name various defects in parts produced by drawing.
14. What are the effects of cold working?
15. Define hot isostatic forging.
16. List out the types of forging machines
17. What are the types of rolling mills?
18. What are the four major draw backs of hot working?
19. Classify the types of extrusion
20. State any two effects produced by Cold-working
21. What are the two basic types of forging process?
22. What do you understand by forging? What are the advantages?
23. List out the forging defects
24. Classify the types of forging machines
25. State the defects in rolled parts.
26. What are the advantages of cold forming?
27. What is the purpose of piercing operation?
28. Name any four limitations of hot forging
29. Write the limitations of hot working process
30. What is the difference between stretch forming and bending?
31. What do you understand by recrystallisation and recrystallisation temperature?
32. What are the general advantages of forging as a manufacturing process?
33. List the functions of Back-up rollers in rolling operation?
34. Discuss in brief open die and closed die forging
35. What is the principle of impact forging?

Part – B (13 – Marks)

1. Classify extrusion process. Explain the backward extrusion and cold extrusion forging operations.
Compare hot and cold extrusion.
2. Explain the mechanism of rolling process with neat sketch. Write about some defects associated with
rolling.
3. Explain hot working and cold working with their advantages and limitations.
4. Explain various forging operation.
5. Describe the ring rolling and thread rolling.
6. Explain the forward and backward extrusion.
 7. How are forging process classified and explain with neat sketches the various forging processes.
8. Classify the types of forging machines and explain any one
9. Explain the forward and back extrusion process
10. Classifies the types of rolling mills and sketches them.
11. List out various forging defects
12. Describe hydrostatic extrusion process.
13. Compare press forging and hammer forging
14. Explain the tube piercing process
15. Distinguish hot and cold extrusion process and briefly explain one in each.
16. Describe the principle of rolling. Write the various kinds of rolling mills along with their applications
17. What are the types of power hammers available and explain the pneumatic hammer with a neat sketch

Part – C (15 – Marks)

1. Explain with neat sketches the process of tube drawing of metals.
2. Describe the principles of rolling and the various sequences of operation of production of V-shape
angles.
3. Classify the extrusion process and explain with neat sketches the various extrusion processes.
4. Describe the difference between a bloom, a slab and a billet. Explain the features of different types of
rolling process.
5. Discuss the effects of temperature, strain rate and friction on metal forming process
6. Explain with a sketch, what is meant by flat strip rolling
7. Explain the procedure for making the head of Bolt by forging operation
8. Name the hand forging operation and explain briefly about them.
9. Explain with a neat sketch of roll forging process.
10. Describe the following processes a. Roll die forging b. Skew rolling c. Ring rolling.
 UNIT – IV
SHEET METAL PROCESSES
Part – A (2 – Marks)
1. What are the advantages of Hydroforming?
2. What is lancing operation that is done on sheet metals?
3. What are the limitations of explosive forming?
4. Define spring back.
5. Why it is necessary to provide proper clearance between the punch and die in a shearing operation?
6. Define spring back effect in sheet forming process.
7. List the advantages of super plastic forming processes.
8. What is the difference between a cut off operation and a parting operation?
9. What is shear angle? Why it is given in punch and die?
10. How sheet metal operations classified and what are they.
11. What is flanging?
12. What are the various types of sheet metal dies?
13. Define bending and list its types.
14. Define explosive forming.
15. Define drawing.
16. What is blanking?
17. What is punching operation?
18. What are the different types of metals used in sheet metal work?
19. Mention any four products produced by spinning process?
20. In which member the clearance should be given for blanking and piercing?
21. What is the difference between stretch forming and bending?
22. List various operations generally performed in a sheet metal shop
23. Show the details of punching process with the help of a simple sketch
24. Give the difference between punching and blanking
25. List the various sheet metal that can be formed in press working
26. Define the term spring back
27. What are the advantages of stretch forming operation?
28. What are the types of special forming processes?
29. What are the advantages of hydro forming process?
30. State the limitations and applications of rubber pad forming process
31. What is metal spinning process?
32. State the advantages and applications of explosive forming process
33. What is peen forming process?
34. What are the advantages and disadvantages of peen forming process
35. What are the applications of super plastic forming process?

Part – B (13 – Marks)

1. An L-shaped part is to be bent in a V-bending operation on a press brake from flat blank 101.6mm by
38.1mm that is 3.96mm thick. The bend of 90° is to be made in the middle of the 101.6 length
a. Determine the dimension of the two equal sides that will result after bend, if the bend radius =
4.76mm. For convenience, these sides should be measured to the beginning of the bend radius.
b. Also, determine the length of the part’s neutral axis after the bend.
c. Should the machine operator set the stop on the press brake relative to the starting length of the
part?
2. Explain the single die and multiple operational die with neat sketch. State their advantages and
 limitations.
3. Explain the various properties of sheet metal.
4. Describe the nibbling and notching operations.
5. Explain the different types of bending process.
6. In detail, explain the coining and embossing.
7. Describe the various method of rubber pad forming and where are these processes used.
8. Explain any one stretch forming operation
9. Define formability and how it is tested?
10. What is drawing operation?
11. Explain the metal spinning operation
12. Describe the magnetic pulse forming process
13. What is deep drawing operation? Explain with a neat sketch.
14. Explain rubber pad forming process
15. Describe the electro hydraulic forming process
16. Describe the explosive forming process
17. How are aluminum kitchen utensils produced?
18. Describe the process of hydro forming
19. Describe the various methods of rubber forming. Where are these processes used?
20. What is super plastic forming?
21. Describe the hydro forming process with the help of neat diagram

Part – C (15 – Marks)

1. Write short notes on (1) sheet bending (2) perforating.
2. Explain the principle, working and applications of magnetic pulse forming process.
3. Enumerate the difference between recovery and recrystallization in the mechanical working of metals.
4. Explain the characteristic features of sheet metal used in forming process
5. Explain peen forming process
6. Find the total pressure, dimensions of tools to produce a washer 5cm outside dia with a 2.4 cm diameter hole,
from a material 4 mm thick, having shear strength of 360 N/mm2
7. Determine a) blank diameter b) least no. drawing operations c) force and energy for the first draw with 40%
reduction to produce a cup of 5 cm in diameter and 7.5cm deep to be drawn from 1.5mm thick drawing steel
with a tensile strength of 315 N/mm2
8. Estimate the blanking force to cut a blank 30mm and 35 mm long from a 1.5 mm thick metal strip, if the
ultimate shear stress of the material is 450 N/mm" Also determine the work done if the percentage penetration is
25% of material thickness
9. A blank has a perimeter of 31.75cm. The metal is 1mm thick cold worked 0.15% carbon steel with a shear
strength of 420 N/mm" and percent penetration of 25%. Two holes of 1.25cm diameter each are to be pierced
during the same stroke when the piece is blanked. What are the
10. forces required for blanking and for piercing? What is the maximum force the press must exert at any one time
without shear?
11. Estimate the blanking force to cut a blank 30 mm wide and 35 mm long from a 1.8mm strip if the ultimate shear
stress of the material is 450 N/mm2 Also determine the work done if the percentage penetration is 25% of
material thickness.
 UNIT – V
MANUFACTURE OF PLASTIC COMPONENTS
Part – A (2 – Marks)
1. What is film blowing? (May 2012) (Nov 2012)
2. Name two important differences between thermoplastics and thermosetting plastics.
3. What is polymerization?
4. What is calendaring?
5. What are the difference types of compression moulding?
6. Define pulforming.
7. What is polythene?
8. Name the common thermosetting plastics.
9. List out any four types of adhesives used in adhesive bonding of plastics.
10. Define poly addition.
11. Write short notes on the application of plastics.
12. What are reinforced plastics and where it is applied?
13. What are the industrial used of fibres and filaments?
14. What is meant by laminates
15. Name some examples of thermoplastics.
16. What are the applications of laminated plastics?
17. Enumerate the advantages of Electro-hydraulic forming process
18. Write any two limitations of Electro-magnetic forming process
19. What are the characteristics of thermosetting plastics?
20. Classify thermoplastics
21. What is meant by high energy rate forming?
22. Name any four thermosetting plastics, used in industries.
23. Give four examples of thermo plastics
24. Give two examples of thermoplastics and thermosetting plastics
25. What is blow moulding process?
26. Which type of plastic is used for manufacturing electrical switches? Why?
27. What is meant by rotational moulding?
28. List the advantages and disadvantages of rotational moulding
29. Define thermoforming
30. What is meant by transfer moulding?
31. Which type of moulding is used for making bottles?
32. What are the types of compression moulding?
33. What is bonding of thermoplastics?
34. List the advantages and disadvantages of transfer moulding
35. What is meant by film blowing?

Part – B (13 – Marks)

1. Briefly explain the working principle and applications of injection moulding process with a neat sketch.

dimension of mould cavity (𝐿𝑐)that will compensate for shrinkage (consider the shrinkage of polyethylene S
2. The nominal length of a part (L) of a part made of polyethylene is to be 80mm. determine the corresponding

= 0.025)
3. Explain the structure of thermoplastics and thermosetting plastic. Compare the thermoplastics
and thermosetting plastics.
4. Write the difference between thermoplastic and thermosetting plastics.
5. Explain the injection blow moulding process.
 6. Explain the calendaring process.
7. Describe any two types of thermoforming process.
8. Describe with a neat sketch the procedure for producing plastic films and sheets by extrusion process.
9. Explain the principle of injection moulding process
10. Describe any method of bonding thermoplastics
11. What is laminating? Explain the low pressure method of laminating
12. Explain the transfer moulding process
13. Why screw injection moulding machine is better than a ram type injection moulding machine?
14. Describe the compression moulding process
15. Describe briefly any two thermoplastics and thermosetting plastics
16. What are the processes used for processing of thermoplastic. Explain any one process with suitable
sketches
17. What is thermoforming process? Explain with a neat sketch
18. Explain how components are fabricated using powder metallurgy Process.
19. (i) Explain the types of Plastics.
(ii) State the purpose of the following plastics: 1.Plasticizers 2.Filler 3.Stablizers
20. (i) Describe the process Equipment for Injection moulding.
(ii) Explain the working principle of plunger and screw type injection machines.

Part – C (15 – Marks)

1. Enumerate the various processes of joining of plastics.
2. Describe with suitable illustration the procedure of producing plastic components by injection moulding.
3. Discuss in detail the various thermosetting and thermo plastics compounds and their application.
4. Describe film blowing operation
5. Explain Rotational moulding
6. Explain blow moulding process with its salient features
7. What are the additives to be mixed in processing plastics and explain the purpose of each.
8. Describe different types of plastics with applications of each type
9. How do thermoplastics differ from thermosetting plastics?
10. Explain various types of thermoforming method shaping Thermoplastics.

Prepared By: J.BOOPALAN/AP/MECH