Faculty: Dr.

Amit Aherwar MP
Subject: Manufacturing Process (120311) 120311
Class: III Sem, Mechanical Engineering (B.Tech.)
Question Bank

Unit-1

Two marks Questions

1. What are the common materials used for pattern making

2. Draw a sketch of a typical mould and name its principal parts.
3. Classify different types of moulds.
4. Define hot working of metals.
5. Define cold working of metals
6. What is recrystalization temperature
7. Summarize the effects of cold working.
8. Identify few application of centrifugal casting.
9. List the different types of patterns.
10. Write the application of core prints.
11. Identify the ideal profile of a sprue.
12. Define core print.
13. Define Casting
14. Describe the essential requirements of a core sand briefly.
15. Explain the advantages of shell moulding briefly.
16. List out the casting defects occur due to improper ramming.
17. Explain Pattern briefly.

Three marks Questions

1. Point out any four casting defects

2. Point out the Materials used for making Patterns.
3. Differentiate Shrinkage and Porosity.
4. Compare the advantages of metal moulds over sand (expendable) moulds .
5. Point out the function of flux in melting metals and alloys.
6. State any four properties of moulding sand.
7. Point out the types of furnace used for melting ferrous material and why.
8. Examine the causes for the formation of blow holes in the sand casting.

Seven marks Questions

1. Describe the preparation of sand moulding process? Explain the various types of pattern
used in Mould Making.
2. Classify the materials used for pattern making and write about them. What are the
allowances given while making Pattern? Explain
Faculty: Dr. Amit Aherwar MP
Subject: Manufacturing Process (120311) 120311
Class: III Sem, Mechanical Engineering (B.Tech.)
3. Classify the different types of moulding sand and explain. Explain the method of moulding
sand testing
4. Explain stir casting method with a sketch. Name any five casting defects and Explain the
remedies for those defects.
5. Explain how the pipes and cylinder liners are made by centrifugal casting process. Briefly
Explain the Principle and operation of CO2 Moulding.
6. Enumerate the steps in sequence for producing Shell Moulding. Explain lost wax -
Investment casting processes with neat sketch.
7. Explain ceramic moulding with a sketch. With the help of neat Sketch, describe in detail,
the process of producing components by pressure die casting.
8. Describe with a neat sketch of cold chamber die casting machine. Describe the procedure
of making castings by the true centrifugal casting and write it advantages and
disadvantages.
9. Briefly describe hot chamber die casting process. Describe any one type of Centrifugal
casting with neat diagram.
10. Enumerate the steps in sequence for producing Shell Moulding. Explain lost wax -
Investment casting processes with neat sketch.
11. Describe the various properties required for the moulding sand. Explain types of cores and
its application.
12. Identify and explain the various steps involved in sand core manufacturing. Explain
squeeze Jolting machine with neat sketch.
13. Explain construction and operation of Blast furnace with necessary sketch. Describe the
constructional feature of cupola furnace.
14. Describe the various properties required for the moulding sand. Explain types of cores and
its application.
15. Identify and explain the various steps involved in sand core manufacturing. Explain
squeeze Jolting machine with neat sketch.
16. How are patterns classified? Describe them with neat sketches and state the uses of each
of them.
17. Write short notes on core making process. Sketch a cupola and label the essential parts.
18. Describe the operation of a cupola Furnace. State the methods of cleaning castings. Explain
any one method.
19. Give broad classification of various manufacturing processes. Also describe the factors
affecting the selection of manufacturing process for a product.
20. State and explain the properties and types of moulding sands.
21. What type of allowances is generally incorporated into a casting pattern? Explain
22. Explain investment casting process. Compare its capabilities and Applications in the
context of weight (size), dimensional tolerance, and economic quantity with sand casting
and die casting processes.
Faculty: Dr. Amit Aherwar MP
Subject: Manufacturing Process (120311) 120311
Class: III Sem, Mechanical Engineering (B.Tech.)
23. Explain investment casting and die casting process with their applications.
24. State and explain various types of casting defects, causes of defects and its remedies.
25. What is pattern? Explain the following patterns with a schematic diagram. (1) Gated
Pattern (2) Follow board Pattern (3) Split Pattern
26. What is the difference between sand and shell mold casting?
27. Draw the schematic sketch of Gating system for casting. Mention the working function of
each Gating system elements.

Unit-2

Two marks Questions

1. Name the common materials used for forging.

2. Describe press forging.
3. What is the difference between the hammer and press forging?
4. What are the common forging defects?
5. What is meant by hot spinning?
6. Specify the merits of different kinds of rolling mills
7. Define angle of bite in rolling.
8. Define lateral Extrusion.
9. Classify the various forming processes.
10. Identify various defects in rolled parts.
11. Analyze why surface finish of a rolled products better in cold rolling than in hot
rolling.
12. Define forging.
13. Differentiate between compound dies and progressive dies.
14. List out some common applications where extrusion is used.
15. Point out the advantage of cold extrusion.
16. Name the t types of forging machines.
17. Define upsetting and Drawing down in forging operation.
18. Sketch the different types of rolling mills.
19. Differentiate between hot and cold forging.
20. Differentiate extrusion and forging.
21. Define fullering.
22. List out any four parts that can be manufactured by shape rolling operations.
23. Define shear angle, why is it given in punches and dies.
24. Define flanging
25. List out test methods for testing formability of material
Faculty: Dr. Amit Aherwar MP
Subject: Manufacturing Process (120311) 120311
Class: III Sem, Mechanical Engineering (B.Tech.)
26. Explain the limitations of Explosive forming
27. List out the advantages of hydro forming process
28. Defines peen forming
29. Define micro forming.

Three marks Questions

1. Explain the steps involved in drop forging with neat sketches

2. With suitable sketches describe open die forging.
3. Formulate the advantages and limitations of closed die forging.
4. Explain flashless forging operation.
5. Explain about Impression die forging.
6. Explain in detail about the defects occurred in forging operation
7. Describe the ring rolling and thread rolling process.
8. Classify and write notes on various rolling stand arrangement in detail.
9. Discuss the types of Rolling mills.
10. Discuss the type’s defects in rolled part.
11. Explain in detail about wire drawing.
12. Explain with neat sketches the process of tube drawing of metals.
13. Explain with a neat sketch the process of Rod Drawing.
14. Explain about Hot and Cold Extrusion.
15. Explain the forward and backward extrusion process.
16. Compare direct and indirect Extrusion process
17. Write short notes on impact extrusion and hydro static extrusion
18. With neat diagram explain the process of forward extrusion. Explain also how hollow
sections can be produced in this process.
19. With suitable sketches describe open die forging.
20. Formulate the advantages and limitations of closed die forging.
21. Differentiate between stretch forming and bending.
22. Analyse the Purpose of detonator in explosive forming.
23. Point out the basic requirement of super plastic forming.
24. Differentiate between a cut-off operation and a parting operation.
25. List the advantages of super plastic forming processes.

Seven marks Questions

1. State the difference between ‘smithing and forging. List the advantage and disadvantage of
each.
2. Explain roll forging and its principal uses. Describe press forging. How does it differ from
drop forging.
Faculty: Dr. Amit Aherwar MP
Subject: Manufacturing Process (120311) 120311
Class: III Sem, Mechanical Engineering (B.Tech.)
3. Explain with neat sketches the following operations:1)upsetting 2)punching 3)bending 4)
drawing down
4. Explain briefly with neat sketches different processes of extrusion discuss their relative
merits and demerits.
5. Describe with a neat sketch any two type of stretch forming operations
6. Write short notes on Sheet bending and perforating operation.
7. Explain the important factors of bending operations.
8. Explain the different types of bending process
9. Analyse the reason for providing proper clearance between the punch and die in a
shearing operation.
10. Explain the Precision forging Process with neat sketch and compare with Closed Die
Forging process.
11. Analyse and Sketch variation in pressure during the Extrusion process by direct and
indirect methods.
12. Draw a simple sketch showing rolling process and make a short note on deformation of
grains in rolling.

Unit-3

Two marks Questions

1. What is a press? Where it is used?

2. Name various parts of power press.
3. Distinguish between piercing and blanking
4. Define lancing operation that is done on sheet metals.
5. What is Piercing?
6. What is lancing?

Three marks Questions

1. Describe the process of hot and cold spinning stating their advantage.
2. Name and explain various power press driving mechanisms.
3. Examine how sheet metal operations classified and what are they.
4. Formulate the categories of sheet metal working processes.
5. Explain spring back effect and how it is overcome in sheet metal work
6. Point out the various types of sheet metal dies.
7. Discuss spring back in bending operation.

Seven marks Questions

1. Explain various sheet metal drawing operations with sketches.
2. Explain the Formability of sheet metals and formability test methods.
Faculty: Dr. Amit Aherwar MP
Subject: Manufacturing Process (120311) 120311
Class: III Sem, Mechanical Engineering (B.Tech.)
3. Compare Conventional forming with high strain rate forming technique
4. Explain Metal spinning operation with a diagram. Summarise the advantages and
application of metal spinning.
5. Describe the nibbling and notching operations. Explain in detail the Coining and Embossing
Process
6. Point out the advantages and limitation of compound dies over progressive dies
7. Analyse the reasons to provide proper clearance between the punch and die in shearing
operation.
8. Differentiate single die and multiple operation die with neat sketch. Discuss the advantages
and limitations of single and multiple die operation

Unit-4

Two marks Questions

1. List out the applications of welding.

2. What are the functions of coatings on shielded electrodes?
3. Describe resistance welding.
4. Define Brazing process
5. Define Soldering Process
6. Define Friction welding.
7. Formulate the process parameters in FSW.
8. Explain thermit welding briefly

Three marks Questions

1. List out the various types of welding.

2. List out the flame characteristics.
3. Define the role flux in welding operation
4. List the advantages of AC equipment over DC equipment in arc welding.
5. Explain the difference between soldering and brazing
6. List any four welding defects.
7. Examine the causes of Welding defects

Seven marks Questions

1. Explain why shielding of weld area during welding is required. Point out the different types of
Oxyacetylene flame by sketches.
2. Explain the principle of Friction Stir Welding. Explain the advantages of Friction Stir Welding
3. Explain the principle and application of Friction Welding Process
Faculty: Dr. Amit Aherwar MP
Subject: Manufacturing Process (120311) 120311
Class: III Sem, Mechanical Engineering (B.Tech.)
4. Briefly explain the principle of operation advantages and limitations of Electron beam
welding.
5. Explain Thermit welding Process with neat sketch
6. Explain in detail the Plasma Arc Welding process and write its applications and demerits.
7. Explain the advantages, disadvantages and limitation of Resistance Welding Process.
8. Differentiate between upset welding and flash welding
9. Explain with neat sketch the principle of resistance welding.
10. Explain the Resistance spot welding Process with a neat sketch
11. Describe the process of Electro Slag Welding and mention their major application.
12. Describe with neat sketch the various components of oxyacetylene gas welding
equipment.
13. Explain the various types of oxy-acetylene flames with sketches. Explain the Manual Metal Arc
Welding Process with neat sketch.
14. Explain about the equipment and operation of GTAW process. Explain about the Advantages
and Disadvantages of GTAW.
15. Explain Gas metal Arc Welding Process with Neat diagram. Explain the Advantages,
Disadvantages and Application of Gas Metal Arc Welding Process
16. Describe the submerged arc welding process with neat diagram. State its advantages and
application of submerged arc welding process.
17. Evaluate why spot welding is commonly used in automotive bodies and in large appliances.
Show that the seam welding is an application of spot welding.
18. Describe various types of welding joints with neat sketch. List out the types of edge
preparation before welding process.
19. Distinguish between Gas Welding and Arc Welding.
20. Distinguish between MIG and TI G Welding
21. List out the types of arc welding process and list out the arc welding equipments and
selection factors for power sources.

Unit-5

Two marks Questions

1. What is meant by Sintering?

2. State an advantage and disadvantage of porosity of particles.
3. What are the differences between blending and mixing?
4. Name two applications of explosive compaction of powders.
5. Give an example for activated sintering technique.
6. What do you mean by "two phase materials concept" in powder metallurgy products?
Faculty: Dr. Amit Aherwar MP
Subject: Manufacturing Process (120311) 120311
Class: III Sem, Mechanical Engineering (B.Tech.)
7. Define the term "Powder Metallurgy".

Three marks Questions

1. Outline the objectives of powder metallurgy process

2. Discuss the advantages and limitations of power metallurgy process.
3. How surface contaminants affect the powder properties?
4. Which process of synthesis of powder is economic and why?
5. Discuss four different methods of powder production.

Seven marks Questions

1. Compare the mechanism of powder production by ball milling and atomization.

2. Discuss on the various aspects of design of die and press in pressurized compaction
techniques with illustration.
3. List the difference between powder rolling and bulk metal rolling.
4. Explain the different stages of manufacturing of powder metallurgy component.
5. Discuss atomization process of producing powders and its advantages?
6. Discuss the type of equipment used and the factors influencing the nature of powders