DEPARTMENT OF MECHANICAL ENGINEERING

II YEAR / III SEMESTER

QUESTION BANK
ME3393-MANUFACTURING PROCESSES
UNIT-1 METAL CASTING PROCESSES
PART-A
1. What is mean by low pressure die casting?
Low pressure (LP) die casting systems are uses the pressure levels of around 0.7 to 1 bar to
feed the molten metal into the mould. In this system, the mould is located above the sprue
and metal flows 'up' the sprue and into the runner system and the casting cavity. The liquid
metal moves under constant pressure until the molten metal solidifies in the die cavity.
2. Write any two applications of low pressure die casting.
(a) LP die casting is mainly used to produce aluminum alloy and magnesium alloy parts, such
as automobile hub in the automobile industry, cylinder block, cylinder head, piston, missile
shell, impeller, wind guide wheel and other castings with complex shape and high-quality
requirements.
(b) It can also be applied to small copper alloy castings, such as pipe fittings, faucets in
bathrooms, etc.
3. Briefly discuss the different types of low pressure die casting systems.
LP systems generally fall into the following three categories:
(a) Unsealed LP system:
In this systems, the metal is transferred from a furnace using a pump. An example of this is
the Cosworth process, where an electromagnetic pump is used to lift the metal up and into the
mould.
(b) Sealed LP system:
This systems uses a furnace that can be sealed and pressurized. In this furnace, one or more
hollow tubes connect to the top of the furnace and extend down into the molten metal. A
mould is placed on top of the furnace, the melt in the furnace is pressured and the molten
metal is forced up through hollow tubes into the mould.
(c) Vacuum-assisted LP system:
Vacuum-assisted LP systems are similar to the sealed LP systems, except that a vacuum is
applied to the casting prior to/at the same time as pressurization of the melt.
4. Write any two advantages and limitations of low pressure die casting.
Advantages:
1. Metal quality is also high because the molten metal used for casting comes from the
middle of the furnace; oxides and inclusions tend to settle to the bottom or rise to the surface.
2. Excellent control of process parameters which can be obtained with a high degree of
automation
3. Good metallurgical quality due to a slow, non-turbulent filling and controlled solidification
dynamics which results in good mechanical and metallurgical properties of the castings,
including low porosity.
4. The castings made are of high quality with very less defects.
Limitations:
1. LP systems require specialized machines i.e. an integral melting furnace capable of being
sealed and pressurized must be present.
2. It has a slower cycle due to the low pressure. Therefore, the number of parts manufactured
per unit time is low.
3. Equipment and maintenance costs are high.
4. It is unsuitable for making thin-walled parts (less than 3 mm).
6. Define tilt pouring.
Tilt pouring, also known as tilt casting, is one variation of the gravity die-casting. Tilt
pouring is a process with the unique feature of transferring the liquid metal into a mould by
simple mechanical means under the action of gravity, yet without surface turbulence.
7. What is the main goal of tilt pouring?
The goal of tilt pouring is to reduce porosity and inclusions by limiting turbulence. It
therefore has the potential to produce very high quality castings.
8. Briefly explain the process of tilt pouring.
In tilt pour casting process, the molten metal is poured into a mould by tilting the mould. This
tilting of the machine is performed at the controlled speed so the metal enters the mould
cavity at the controlled speed and with the minimum air intake that results in the inner casting
purity. In this process, once the metal is poured into the pouring cups, the mold is slowly
rotated to the vertical position. Under gravity, the metal slowly fills the mold cavity at a
constant rate. Solidification starts as soon as the metal enters the mould.
9. What is the main difference between traditional tilt pouring and reverse tilt pouring?
In traditional tilt-pouring the mould parting line is perpendicular to the floor during the
solidification phase, while in reverse tilting the parting line is parallel to the floor.

10. Write any two applications of tilt pouring.

(a) This process is used for casting materials with a high propensity to oxidation and foaming,
such as aluminum gravity die casting, and aluminum-bearing copper alloys, in particular
brass gravity die casting.
(b) Industrial applications that benefit from tilt pour permanent mold casting include: air
cylinders, base castings, cold plates, couplings, compressor bodies, differential housings, gear
box housings, pistons, suspension components, valve bodies, hydraulic cylinders etc.
11. Write any two advantages and limitations of tilt pouring.
 Advantages:
 Homogeneous casting structure is possible.
 Repeatability of process parameters is possible.
 It can produce castings with improved surface finish.
 Tighter tolerances are achieved than conventional sand castings.
 Metal yield is better as the wastage of metal is minimal.
 Disadvantages:
 Size of the part produced is limited to usually less than 10 ko
 2. It is not possible to produce complex shaped parts.
12. Name the alloys which are generally die cast. Why are aluminium alloys preferably
cast in cold chamber die casting machines?
Zinc, aluminium, magnesium, copper, lead, tin and uncommon ferrous alloys are generally
die cast.
Cold chamber die casting is more suitable for metals with high melting points and
corrosive properties such as aluminum. So, cold chamber die casting is preferred for
aluminium alloys.
13. What function of core ?
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.
14. What are the different types of furnaces used for casting.
1.Cupola Furnace.
2.Open Hearth furnace
3.Crucible Furnace.
4.Pot Furnace.
5.Electric Furnace.
15. Define AFS grain- fineness number.
It is defined as the ratio between the total products and total percentage of sand retained on
pan and each sieve.AFS grain fineness number =sum of products /total sum of the % of sand
retained on pan and each sieve.
16.Mention the specific advantages of CO2 moulding process
• Gives strength and hardness to core.
• Process cost is less.
• It saves time on heating.
• It can be stored for long use.
17. Explain the term fettling.
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.
18. What are the applications of casting?
Transportation vehicles (in automobile engine and tractors)
• Machine tool structures
• Turbine vanes and power generators
• Mill housing
• pump filter and valve
19. Which process is called lost waxing method? Why?
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 precoated wax pattern.
20. Mention any two advantages and disadvantages of die casting.
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.
PART-B
1. (i) Describe the preparation of sand moulding process.
(ii) Explain the various types of pattern used in Mould Making.
2. (i)Classify the materials used for pattern making and write about them.
(ii) What are the allowances given while making Pattern? Explain
3. (i) Classify the different types of moulding sand and explain.
(ii) Explain the method of moulding sand testing
4. (i) Describe the various properties required for the moulding sand.
(ii) Explain types of cores and its application.
5. Identify and explain the various steps involved in sand core manufacturing.
6. (i) Explain squeeze Jolting machine with neat sketch.
(ii) Explain sand Slinger machine with neat sketch.
7. (i) Explain the Jolting Machine with neat sketch.
(ii) Explain construction and operation of Blast furnace with necessary sketch.
8. (i) Describe the constructional feature of cupola furnace.
(ii) Describe the operation of Cupola furnace with necessary sketch.
9. (i) Enumerate the steps in sequence for producing Shell Moulding.
(ii) Explain lost wax - Investment casting processes with neat sketch.
10. (i) Explain ceramic moulding with a sketch.
(ii) With the help of neat Sketch, describe in detail, the process of producing
components by pressure die casting.
PART-C
11. (i) Describe with a neat sketch of cold chamber die casting machine.
(ii) Describe the procedure of making castings by the true centrifugal casting and
write it advantages and disadvantages.
12. (i) Briefly describe hot chamber die casting process.
(ii) Describe any one type of Centrifugal casting with neat diagram.
13. (i) Explain how the pipes and cylinder liners are made by centrifugal casting
process.
(ii) Briefly Explain the Principle and operation of CO2 Moulding.
14. (i) Explain stir casting method with a sketch.
(ii) Name any five casting defects and explain the remedies for those defects.
15. Identify the following casting defects.Write their causes with remedies.

UNIT-2 METAL JOINING PROCESSES

PART-A
1. What is diffusion welding?
Diffusion welding is a solid state joining process in which the strength of the joint results
primarily from diffusion. Diffusion means movement of molecules or atoms from wenst high
concentration region to low concentration region. In this welding process both the welding
plates are placed one over other in high pressure and temperature for a long period of time.
This high pressure force starts diffusion between interface surfaces.
2. Write down the stages involved in diffusion welding.
Stage 1: Deformation and interfacial boundary formation.
Stage 2: Grain boundary migration and pore elimination.
Stage 3: Volume diffusion pore elimination.
3. What are the advantages of diffusion welding?
1. Plastic deformation at surface is minimal.
2. There is no limitation in the thickness of workpieces.
3. The bonded surface has the same physical and mechanical properties as the base but
material.
4. The diffusion bonding is able to help us to build high precision components with complex
shapes. Also, the diffusion is flexible.
4. Mention the limitations of diffusion welding.
1. It is a time consuming process due to low productivity.
2. Very thorough surface preparation is required prior to welding process.
3. The mating surfaces must be precisely fitted to each other
4. It is relatively high initial investments in equipment.
5. List down the applications of diffusion welding.
1. It is used in joining of high-strength and refractory metals based on titanium in aerospace
and nuclear industries.
2. Diffusion welding is usually used on sheet metal structures such as nuclear and electronics
industries.
6. What is adhesive bonding?
Adhesive Bonding is the process of joining two surfaces together, usually with the creation of
a smooth bond. This may involve the use of glue, epoxy, or one of a wide range of plastic
agents which bond either through the evaporation of a solvent or through curing via heat,
time, or pressure.
7. Define adhesive.
Adhesive is a filler material that binds parts together. It is a non-metallic substance, mostly a
polymer. The parts being joined are called “adhenands”.
8. List the advantages of adhesive bonding.
1. Plastic deformation at surface is minimal.
2. There is no limitation in the thickness of workpieces.
3. The bonded surface has the same physical and mechanical properties as the base material.
4. The diffusion bonding is able to help us to build high precision components with ant
complex shapes. Also, the diffusion is flexible.
9. Write the disadvantages of adhesive bonding.
1. They are not suitable for high temperature services.
2. Bonding and curing is a lengthy process.
3. Self-life of the adhesives is short and some may require special storage conditions such as
refrigeration.
4. Surface preparation is essential.
10. What are the applications of adhesive bonding?
1. Adhesive bonding is used across many industries including automotive, air aerospace,
medical and even textiles.
2. Bonding of metal to non-metals especially plastics is the major application of adhesive
bonding.
3. Bonded joints are used as an alternative to riveting for aircraft structures.
4. Widely applicable in fastening of stiffeners to the aircraft skin and in assembling
honeycomb structures in aircraft
11. List out any four arc welding equipment.
The most commonly used equipments for arc welding are as follows:
(a) A.C or D.C. machine
(b) Wire brush
(c) Cables and connectors
(d) Ear thing clamps
(e) Chipping hammer
12. What are the special features of friction welding?
 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.
13. Define resistance welding process.
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.
14.How can slag inclusions in welding be avoided?
• Avoid multi layer welding
• Reduce arc length
• Increase electrode angle
• Avoid using large electrode
15. How does brazing differ from braze welding?
Brazing Braze Welding

The filler alloy is fed to one or more The filler alloy is deposited

points in the assembly and it isdirectly at the point where it is

drawn into the rest of the joint by desired.

capillary action.

16. Mention the applications of friction welding.

• Used in refrigeration.
• Used in super alloys.
• Making simple forging.
• Production of taper and reamer drills
• Production of axle shafts , valves and gears.

17. What is ‘Brazing’

It is defined as the technique of joining two dissimilar or similar materials by addition of
special filler material. Brazing gives a much stronger joint than soldering but requires greater
heat which cannot be obtained from copper in soft soldering.
18. Classify various ARC welding processes
(i) Arc welding
• Carbon arc
• Metal arc
• Metal inert gas
• Tungsten inert gas
• Plasma arc
• Submerged arc
• Electro-slag
19. Name the chemicals used in flux Manufacture.
1.Chlorides
2.Borax and boric acid.
3.Borates
4.Fluorides.
20. What is the purpose of flux?
 It acts as shield to weld.
 To prevent atmospheric reaction of molten metal with atmosphere.
PART-B
1. (i) Describe various types of welding joints with neat sketch and list out the types
of edge preparation before Welding Process.
2. (i) Distinguish between Gas Welding and Arc Welding.
(ii)Distinguish between MIG and TIG Welding
3. (i) List out the types of arc welding process and list out the arc welding
Equipments and selection factors for power sources.
(ii) Describe with neat sketch the various components of Oxy- Acetylene gas
welding equipment.
4. (i) Explain the various types of oxy-acetylene flames with sketches.
(ii) Explain the Manual Metal Arc Welding Process with neat sketch.
5. (i) Explain about the equipment and operation of GTAW process.
(ii) Explain about the Advantages and Disadvantages of GTAW.
6. (i) Explain Gas metal Arc Welding Process with Neat diagram
(ii) Explain the Advantages, Disadvantages and Application of Gas Metal Arc
Welding Process
7. (i) Describe the submerged arc welding process with neat diagram.
(ii) State its advantages and application of submerged arc welding process.
8. (i) Describe the process of Electro Slag Welding and mention their major
application.
(ii) Explain the Resistance spot welding Process with a neat sketch
9. (i) Explain with neat sketch the principle of resistance welding.
(ii) Differentiate between upset welding and flash welding.
10. (i) Explain the Advantages, Disadvantages and limitation of Resistance Welding
Process.
(ii) Explain in detail the Plasma Arc Welding process and write its applications and
demerits.
PART-C
11. (i) Explain Thermit welding Process with neat sketch.
(ii) Briefly explain the principle of operation advantages and limitations of
Electron beam Welding.
12. (i) Explain the principle and application of Friction Welding Process.
(ii) Explain the principle of Friction Stir Welding.
13. (i) Explain the advantages of Friction Stir Welding.
(ii) Compare and Contrast Brazing and Soldering Process.
14. Classify and enumerate the various welding defects with causes of occurrences
and describe a method of detecting cracks on a weld surface.

15. Identify the welding defects. Write their causes with remedies
 UNIT-3 BULK DEFORMATION PROCESSES
PART-A
1. What is diffusion welding?
Diffusion welding is a solid state joining process in which the strength of the joint results
primarily from diffusion. Diffusion means movement of molecules or atoms from wenst high
concentration region to low concentration region. In this welding process both the welding
plates are placed one over other in high pressure and temperature for a long period of time.
This high pressure force starts diffusion between interface surfaces.
2. Write down the stages involved in diffusion welding.
Stage 1: Deformation and interfacial boundary formation.
Stage 2: Grain boundary migration and pore elimination.
Stage 3: Volume diffusion pore elimination.
3. What are the advantages of diffusion welding?
1. Plastic deformation at surface is minimal.
2. There is no limitation in the thickness of workpieces.
3. The bonded surface has the same physical and mechanical properties as the base but
material.
4. The diffusion bonding is able to help us to build high precision components with complex
shapes. Also, the diffusion is flexible
4. Mention the limitations of diffusion welding.
1. It is a time consuming process due to low productivity.
2. Very thorough surface preparation is required prior to welding process.

3. The mating surfaces must be precisely fitted to each other

4. It is relatively high initial investments in equipment.
5. List down the applications of diffusion welding.
1. It is used in joining of high-strength and refractory metals based on titanium in aerospace
and nuclear industries.
2. Diffusion welding is usually used on sheet metal structures such as nuclear and electronics
industries.
6. What is adhesive bonding?
Adhesive Bonding is the process of joining two surfaces together, usually with the creation of
a smooth bond. This may involve the use of glue, epoxy, or one of a wide range of plastic
agents which bond either through the evaporation of a solvent or through curing via heat,
time, or pressure.
7. Define adhesive.
Adhesive is a filler material that binds parts together. It is a non-metallic substance, mostly a
polymer. The parts being joined are called “adhenands”.
8. List the advantages of adhesive bonding.
1. Plastic deformation at surface is minimal.
2. There is no limitation in the thickness of workpieces.
3. The bonded surface has the same physical and mechanical properties as the base material.
4. The diffusion bonding is able to help us to build high precision components with ant
complex shapes. Also, the diffusion is flexible.
9. Write the disadvantages of adhesive bonding.
1. They are not suitable for high temperature services.
2. Bonding and curing is a lengthy process.
3. Self-life of the adhesives is short and some may require special storage conditions such as
refrigeration.
4. Surface preparation is essential.
10. What are the applications of adhesive bonding?
1. Adhesive bonding is used across many industries including automotive, air aerospace,
medical and even textiles.
2. Bonding of metal to non-metals especially plastics is the major application of adhesive
bonding.
3. Bonded joints are used as an alternative to riveting for aircraft structures.
4. Widely applicable in fastening of stiffeners to the aircraft skin and in assembling
honeycomb structures in aircraft
11. What are the four major drawbacks of hot working?
 As hot working is carried out at high temperatures, a rapid
oxidation orscale 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.

12. Explain the term Extrusion process.

The extrusion process consists of compressing a metal inside a chamber to force
through a small opening which is called as die. Any plastic material can be successfully
extruded. 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 is
placed in the container and forced out through a steeldie with the the help of armour plunger.
13. What are the disadvantages of forging processes?
• Complicated shapes cannot be produced.
• Generally used for large parts.
• Because of cost of dies, process is costly.
14. What is wire drawing.
Drawing of metal through a small aperture die and wounding in the form of coil is called wire
drawing. The aperture is generally below 16mm diameter.
15.What is meant by deep Drawing.
It is the process of making cup shaped parts from sheet metal blanks, where the depth of the
cup is greater than that of the diameter of the cup.
16. Define neutral point in rolling process.
Neutral point is the point in the are of contact where the roll velocity and the stripm velocity
are the same.
17. What is strain rate sensitivity?
Strain rate is the change in strain (deformation) of a material with respect to time. It is the
most important mechanical characteristic of a superplastic material which is its high strain
rate sensitivity of flow stress
18. What is roll-pass design?
Designing the sequence of intermediate shapes and corresponding rolls is called roll- pass
design.
19. What does angle of bite in rolling mean?
The angle subtended by the centre of the roll with radial force in rolling operations is called
angle of bite or angle of contact
In other words, it can be defined as an angle between first contact of metal and radius of the
roll. It joins the opposing rolls and the centres of them when metal is rolled.
20. How the shaping operations are classified?
In general, the shaping operations are classified into two main types: primary and secondary.
Primary shaping operations form the overall shape of the product or the component such as
sheet, bar, plate, or some other preliminary form.
Secondary shaping operations take the preliminary form and alters its shape further 10 a final,
precisely shaped version of the product that will meet the product requirements. Secondary
operations further improve the properties, surface quality, dimensional accuracy, tolerance,
etc. These operations are primarily used to remove metal to develop a specific form from the
unfinished piece.
PART-B
1. (i) Explain hot working and cold working processes.
(ii) Explain various forging operation .
2. (i) Explain the steps involved in drop forging with neat sketches
(ii) With suitable sketches describe open die forging.
3. (i) Formulate the advantages and limitations of closed die forging.
(ii) Explain the Precision forging Process with neat sketch and also compare with
Closed Die Forging process.
4. (i) Explain flashless forging operation.
(ii) Explain about Impression die forging.
5. (i) Explain in detail about the defects occurred in forging operations. (ii) Draw a
simple sketch showing rolling process and make a short note on deformation of grains in
rolling
6. (i) Describe the ring rolling and thread rolling process
(ii) Classify and write notes on various Rolling Stand Arrangement in detail.
7. (i) Discuss the types of Rolling mills.
(ii) Discuss the types defects in rolled parts. A 300 mm wide strip 25 mm thick is
fed through a rolling mill with two powered rolls each of radius = 250 mm. the work
thickness is to be reduced to 22 mm in one pas at a roll speed of 50 rev/min. the work
material has a flow curve defined by K = 275 MPa and n = 0.15 and the coefficient of friction
between the rolls and the work is assumed to be 0.12. Determine if the friction is sufficient to
permit the rolling operation to be accomplished. if so, calculate the roll force, torque and
horsepower.
8. (i) Explain in detail about wire drawing
(ii) Explain with neat sketches the process of tube drawing of metals

PART-C
9. (i) Explain with a neat sketch the process of Rod Drawing.
(ii) Explain about Hot and Cold Extrusion.
10. Explain the forward and backward extrusion process
11. Analyse and Sketch variation in pressure during the Extrusion process by direct
and indirect methods.
12. (i) Compare direct and indirect Extrusion process
(ii) Write short notes on impact extrusion and hydro static extrusion.
13. With neat diagram explain the process of forward extrusion. Explain also how
hollow sections can be produced in this process.
UNIT-4 SHEET METAL PROCESSES
PART-A
1. What is incremental forming?
Incremental forming, also known as incremental sheet forming, is a dieless metalworking
process that is suitable for small lot productions of a wide variety of complex parts. The
desired shape is obtained by applying localized pressure with a deforming tool that moves
along a metal sheet. A sheet is shaped into the final part shape by progressively applying
small increments of deformations using a round-tipped or hemispherical head tool, typically 5
to 20 mm in diameter.
2. Write classifications of incremental forming.
Incremental forming can be classified into the following categories:
(a) Conventional Incremental Sheet Forming (CISF)
(i) Single-point incremental forming or Negative dieless forming
(ii) Two-point incremental forming or Positive dieless forming
(b) Hybrid Incremental Sheet Forming (HISF)
(i) Single-point incremental hydro-forming
(ii) Two-point incremental forming with partial die
(iii) Two-point incremental forming with full die

3. Explain briefly the conventional incremental forming operation.

In this process, generally a sheet of metal is deformed by progressive and localized plastic
deformation using a simple hemispherical/ballpoint tool, and this path of the forming tool is
controlled by a CNC machine. The forming tool moves over the surface of the sheet and
results the final shape. There is no other tool or external pressure applied for deforming the
sheets into the desired shape.
4. Write brief description about hybrid incremental forming.
This process is the modified forms of conventional incremental forming. In this process,
forming tool moves over the surface of sheet metals, while the another side of surface of
sheet metals is supported by pressurized hydraulic fluid, partial die or full die to get the desire
shape and size.
5. List the advantages of incremental forming.
1. Useable parts can be formed directly from CAD data with a minimum of specialized
tooling. A conventional CNC milling machine or lathe can be used for this process.
2. The process does not require either positive or negative dies; hence, it is dieless.
3. Changes in part design sizes can be easily and quickly accommodated, giving a high
degree of flexibility.
4. Making metal rapid prototypes is normally difficult, but easy with this process.
5. The small plastic zone and incremental nature of the process contribute to increased
formability, making it easier to deform low formability sheet.
6. Mention the limitations of incremental forming.
1. Forming time is much longer than competitive processes such as deep drawing.
2. This process is limited to small-size batch production.
3. The forming of right angles cannot be done in one step, but requires a multi-step process.
7. List down the applications of incremental forming.
There are a number of areas, where high precision of the products is required for the accuracy
of the performance. Areas of products can manufacture by incremental forming are as
follows:
(a) Aerospace industry: Instrument panel, body panel, passenger seat cover, etc.
(b) Automobile: Door inner/outer panel, hood panel, engine cover, etc.
(c) High customized products: Denture plate, ankle support, metal helmet, etc
8. 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, trade marks, specifications, etc.
On the sheet metal.
9. What are the factors affecting shearing operation?
Shape and material of punch
Die,speedof punching,lubrication
Clearance between punch & die.
10. Define Blanking.
A finite shape of sheet metal is removed and blocked by shearing the entire contour using a
die and a punch. The portion removed, which is the required part is called as blank and the
operation is called as blanking.
11.What is meant by Dimpling.
First hole is punched and then it is expanded into a flange. flange may be produced by
piercing with a sharp punch when ther bend angle is less than900, as n fittings with conical
ends.this process is also called as Flairing.
12.Define Notching.
It refers to the removing pieces from the edge. In this process, the metal is removed from the
side (or) edge of a sheet to get the desired shape.
13.Define Stretch forming.
The sheet metal is placed under a tensile load over a forming block and stretching it beyond
its elastic limit and to the plastic range, thus cause permanent set to take place.this process is
useful in making prototype models of aircraft and automotive parts
14.Define Wrinkling
It is caused by compressive stresses in the plane of the sheet . It can be objectionable or can
be useful in imparting stiffness to parts. It can be controlled by proper tool and die design.
15. Define hydro forming process.
1) Hydro - mechanical forming
2) Electro - hydraulic forming Hydro - mechanical forming: In this method , the blank
is placed over the punch whose shape is similar to inner of the find work piece. 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.
16.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 similliar 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.
17.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 byforming the part.
18.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.
19. What is punching operation ?
It is the cutting operation with the help of which various shaped holes are produced in the
sheet metal. 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.
20. What is super plastic forming operation ?
Superplastic forming is a metalworking process for forming sheet metal. It works upon the
theory of superplasticity, which means that a material can elongate beyond 100% of its
original size.
PART-B
1. Summarise the Sheet metal Characteristics
2. Write short notes on the following
(i) Shearing
(ii) Blanking
(iii) clearance in shearing
(iv) Spring back in bending
3. Explain the different types of bending process .
4. (i) Explain various sheet metal drawing operations with sketches.
(ii) Describe with a neat sketch any two type of stretch forming operations
5. (i) Explain the Formability of sheet metals and formability test methods.
(ii) Compare Conventional forming with high strain rate forming technique.
6. (i) Explain with a neat sketch hydro forming.
(ii) Describe Rubber Pad Forming with suitable sketch.
7. (i) Explain Metal spinning operation with a diagram.
(ii) Summarise the advantages and application of metal spinning.
8. (i) Formulate the process variables in Explosive Forming and explain explosive
forming with sketch.
(ii) Describe Magnetic Pulse Forming with a neat sketch.
9. With an application examples, explain the deep drawing operation.
10. Explain any one stretch forming method.
11. Enumerate with a neat sketch any two types of stretch forming operations.
12. Write a note on the characteristics and formability of sheet metals.
13. Write short notes on formability tests for elastic-plastic deformation.
14. Describe forming limit diagram.
15. Explain the various sheet metal forming processes with its important characteristics
PART-C
16. (i) Explain peen forming with sketch.
(ii) Describe super plastic forming and Explain with neat sketch.
17. (i) Explain Micro forming.
(ii) Describe the die cutting and slitting operations.
18. (i) Describe the nibbling and notching operations
(ii) explain in detail the Coining and Embossing Process.
19. (i) Point out the advantages and limitation of compound dies over progressive dies
(ii) Analyse the reasons to provide proper clearance between the punch and die in
shearing operation.
20. (i) Differentiate single die and multiple operation die with neat sketch.
(ii) Discuss the advantages and limitations of single and multiple die operation.

UNIT-5 MANUFACTURE OF PLASTIC COMPONENTS

PART-A
1. What is the rotational moulding of plastics?
In this process, a measured quantity of polymer powder is placed in a thin walled metal
mould. The mould is closed and it is rotated about two mutually perpendicular axes as it is
heated.
2. What is the need for rotational moulding in manufacturing plastic components?
The rotational moulding is needed to make thin walled hollow parts.
3. State any four applications of rotational moulding.
1. It is used to produce toys using PVC.
2. It is used to make large containers of polyethylene.
3. It is used to make petrol tanks for motorcars from polyethylene and nylon.
4. Metallic or plastic inserts are moulded by this process.
4. Define film blowing.
The process in which a continuous tubular film is fabricated of which diameter varies from
few centimetres to many metres is called film blowing.
5. Describe briefly the principle of film blowing.
Crystalline sharp melting polymers such as nylon or polyethylene terephthalate PET are very
much suited for film productions by melt casting techniques. Initially, the heated plastic
powder is extruded by using extrude machines called extruder. In this extruding process, the
thin film is produced.
After extruding the thin film, it is stretched by pulling rollers through the chilled drum in the
reeling wheel. The thin film is cooled in the chilled drum and the rollers are used to pull the
film from chilled drum. The reeling wheel is used to make the film roll.
6. What are the applications of film blowing?
1. Industry packaging (e.g. shrink film, stretch film, bag film or container liners)
2. Consumer packaging (e.g. packaging film for frozen products, shrink film for transport
packaging, food wrap film, packaging bags and seal packaging film)
3. Laminating film (e.g. laminating of aluminium or paper used for packaging for example
milk or coffee)
4. Barrier film (e.g. film made of raw materials such as polyamides and Ethylene-Vinyl
Alcohol Copolymer (EVOH) acting as an aroma or oxygen barrier used for packaging food
such as cold meats and cheese).
7. What is calendaring in processing of plastics?
Calendering process is used for sheet making. A calender is a series of hard pressure rollers
used to form or smooth a sheet of material such as paper or plastic film. In this process, the
plastic compounds composed of resin, filler, plasticizer and other additives are heated for
sometime and passed through the heated rollers
8. Mention the applications of calendaring.
1. It is used for making PVC, tapes, and rainwear with very high production rate.
2. It is also used for making floor tiles and cellulose acetate sheets
9. Write down the main distinct sections in extrusion process.
The screw has three distinct sections.
1. Feed section connects the material from hopper into the central region of the barrel.
2. Melt section in which plastic starts to melt.
3. Pumping section in which additional shearing and melting occur.
10. State the applications of screw type extrusion process.
1. It is used to make tubes, sheets, films, pipes, ropes and other profiles.
2. Complete shapes with constant cross sections can be extruded with relatively inexpensive
tooling.
3. Plastic extruders are also extensively used to reprocess the recycled plastic waste or other
raw materials after cleaning, sorting and/or blending.
11. Define thermoforming.
Thermoforming is the process in which the thermoplastic sheets are formed with the
application of heat and pressure in a mould. Thin sheet (up to 1.5 mm) and thick sheet (about
3 mm) can be formed easily.
12. Mention the various methods of thermoforming.
1. Vacuum forming
2. Pressure forming
3. Matched die forming.
13. What are the advantages of thermoforming?
1. It is extremely adaptive to design requirement.
2. It is useful for rapid prototype development.
3. Initial setup cost is low.
4. Production cost is low.
5. There are less thermal stresses than injection moulding and compression moulding.
6. Dimensional stability is good.
14. List down various disadvantages of thermoforming.
1. Surface finish is poor.
2. Parts may have non-uniform wall
3. All parts need to be trimmed.
4. Ribs and bosses cannot be moulded easily.
5. Limited number of materials can be used.
6. Very thick plastic sheets cannot be formed.
15. Write down the applications of thermoforming process.
1. It is very much useful for making trays, drink cups and refrigeration door lines.
2. It is used for making panels for shower stalls and advertising signs.
3. Thin gauge parts made using thermoforming are primarily used to package or contain a
food item, disposable cups, containers, lids, blisters and clamshells.
16.What are the different types of compression moulds?
1. Flash type
2. Landed positive type
3. Positive type
4. Semi positive type.
17. What are the applications of compression moulds?
1. It is used to make dishes, handles, containers, taps and fittings.
2. Electrical and electronic components, washing machine agitators and housings are made by
this process.
18. Explain briefly how transfer moulding process is carried out.
Transfer moulding is a modification of compression moulding. In this process, the amount of
material is measured and inserted in a separate chamber called transfer pot before the
moulding process takes place. The material is then preheated and loaded into a pot. A plunger
is then used to force the material from the pot through the sprue and runner system into the
mould cavities. The mould remains closed as the material is inserted and opened to release
the part from the runner. The mould walls are heated to a temperature above the melting point
of the mould material. It allows a faster flow of material through the cavities.
19. List down the points to be considered while designing the transfer mould.
1. Flow of materials should be easy.
2. Ejecting of mould should be easy.
3. Heating of all the parts should be uniform.
20. What are the advantages of transfer moulding?
1. Before completely filling the plastic in the mould cavity, little pressure is maintained inside
the mould and it will create full liquid pressure inside the cavity.
2. The viscosity of flow material is reduced.
3. Uniform thickness of parts can be obtained.
4. Durable and dimensionally stable parts can be obtained.
21. Mention the limitations of transfer moulding.
1. The scrap rate for transfer moulded parts will usually be higher than compression moulded
parts.
2. It is more complex than compression moulding.
3. Warpage is more of a problem because the flow of transfer materials is softer and shrinks
more than compression grade materials.

PART-B
1. (i) Explain the types of Plastics.
(ii) Explain Properties of Plastics.
2. (i) Discuss about a few Commercial Plastics
3. (i) List out and write the various processes of joining plastics.
(ii) Summarise the various differences between thermoplastics and thermosetting
plastics.
4. (i) Explain the injection blow moulding process.
(ii) Discuss injection moulding process of plastic products
5. (i) Describe the process Equipment for Injection moulding
(ii) Explain the working principle of plunger and screw machines.
6. (i) Explain Positive, semi positive and flash type Compression Moulding.
(ii) State the typical industrial applications of Transfer moulding.
7. (i) Explain transfer moulding. Discuss its advantages and limitations.
(ii) Compare blow moulding and rotational moulding.
8. (i) Compare blow moulding and rotational moulding.
(ii) Explain the Process Rotational moulding
9. Explain with neat diagrams the thermoforming process. State its advantages over
other processes.
10. Explain how plastic sheets are manufactured by thermo forming method.
11. Describe any two types of thermoforming process.
12. Describe the working principle of film blowing and thermoforming.
13. Why is the thermoforming a valuable method for the plastic manufacturer? Explain
the process with neat sketch.
14. Sketch and explain the principle of vacuum forming process for plastics.
15. Discuss the processing of thermosetting plastics.
16. Describe the compression moulding process.
17. Describe the following plastic processing methods with neat sketches (i) Compression
moulding (ii) Blow moulding.
18. Explain positive, semi positive and flash type compression moulding.
19. What is transfer moulding? Discuss it advantages and limitations.
20. What is laminating? Explain the high pressure method of laminating.
21. Explain the various moulding process for reinforced plastics.
22. Enumerate various methods of bonding thermoplastics.
23. Describe any one method of bonding thermoplastics.
24. Explain briefly the following methods of bonding of thermoplastics:
I. Fusion bonding
II. Vibration welding
III. Solvent bonding
IV. Induction welding.
PART-C
25. (i) Explain the Extrusion blow moulding process.
(ii) Describe the Blown- film extrusion process.
26. (i) Explain the calendaring process.
ii) Enumerate and write about various methods of bonding thermoplastics
27. (i) Discuss in detail the various thermosetting and thermoplastic compounds and
their applications.
(ii) Describe any two types of thermoforming process.
28. Explain various types of thermoforming method shaping thermoplastics
29. Explain the structure of thermo plastic and thermosetting plastics.
30. Explain the various methods of Bonding of Thermoplastics.

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