UNIT I Metal Casting Process

1. State any four properties of moulding sand. a. Refractoriness withstanding high temperature b. Permeability - Allowing the hot gases to escape c. Strength - withstand the shape. d. Collapsibility - ability to break after solidification e. Stability - not expanding or contracting f. Adhesiveness - to surrounding walls g. Cohesiveness - Between sand particles h. Reusability 2. Name the difference furnaces employed for metal casting. 3. Which type of furnace is suitable for melting ferrous alloys. a. Cupola - ferrous b. Induction - ferrous c. Crucible (coke, oil) d. Direct and indirect arc 4. What do you mean by pattern & materials used for making pattern? Patterns has replica shape of final product are used to mold the sand mixture into shape of the casting. Its normally made of Wood Aluminum Steel Cast iron Plastic Wax 5. What all the factors you will consider before selecting your pattern a. Size, Shape, Complexity. b. Surface finish required. c. Dimensional accuracy. d. Quantity of molding. 6. State any four types of pattern a. Single piece b. Split c. Loose piece d. Match plate e. Sweep f. Skeleton g. Segmental h. Shell 7. Write a note on chilled casting. The chills are used to provide directional solidification or to increase the rate of solidification where the high hardness is required. Carbon becomes iron carbide to make soft and highly malleable metal.

8. Compare the advantage of metal moulds over sand moulds 9. Mention any two merits and demerits of die casting Advantage Disadvantage a. Great accuracy i. Only small parts b. Good rate of ii. Only for non ferrous production iii. Suitable for mass c. No sane inclusion production d. Less defects iv. High equipment cost e. Long life 10. What is the need of special casting process a. The sand moulds may be used only once, because the mould is destroyed after the metal has solidified. This will increase the cost of production. b. The sand moulds cannot maintain the tolerance and smooth surface finish 11. List any four components manufactured using centrifugal casting process a. Water pipes, b. Gears, c. Bush bearings, d. Fly wheels, e. Piston rings, f. Brake drum, g. Gun barrels 12. Principles of induction furnace

Electromagnetic induction is the principle used in induction furnace. The heating by the induction method occurs when an electrically conductive material is placed in a varying magnetic field. Induction heating is a rapid form of heating in which a current is induced directly into the part being heated. 13. Merits and demerits of investment casting Advantage: a) Good dimensional accuracy b) Relatively inexpensive mold c) Rapid production rates possible d) Complex shapes Disadvantage: a. Long production cycle

b. Mold is not reusable c. Many processing steps are required 14. What is core and its requirement Core: It a device used in casting and molding processes to produce internal cavities Core Prints: It is an added projection on the pattern and it forms a seat in the mold on which the sand core rests during pouring of the mold. Core Chaplets: Additional support provided at the mold cavity.

UNIT II JOINING PROCESS

1. What are the advantages of AC equipments over DC machines in arc welding.

2. Why is the flux used in soldering and brazing?

a. Dissolve oxides from the surfaces to be joined. b. Reduce surface tension of molten filler metal i.e. increasing its wetting action or spreadability. c. Protect the surface from oxidation during joining operation i. Solder Fluxes- Zinc chloride, ammonium chloride, rosin. ii. Brazing flux - borates, fluorides, chlorides, borax& boric acid
15. Differentiate the terms mould and core. Mould: It is the cavity of the required shape made in moulding sand or in other material. Core: It is device used in casting and molding processes to produce internal cavities 16. What is core venting? A vent used for the release of air, or, sometimes gas in a mold or core. Slots or screen act as the vent and are used in such a way that air or gas built up within a mold or core is permitted to escape. 17. Explain the term fettling Fettling is cleaning of metal casting. It involves a) Removal of dry sand cores b) Removal of gates and risers c) Removal of unwanted metal projection and fins d) Removal of adhered sand and oxide scale 1. Wire brushing 2. Tumbling 3. Sand blasting 4. Shot Blasting 5. Hydro blasting 6. Pickling 3. List out any four arc welding equipments Consumable

i. ii. iii. iv. v. vi. vii. viii. ix.

Shielded Metal Arc Welding Submerged Arc Welding Gas Metal Arc Welding Flux-Cored Arc Welding Electro-gas Welding Electro-slag welding Gas Tungsten Arc Welding Plasma Arc Welding Carbon Arc Welding

Non Consumable

4. What is the principle of resistant welding Apply force and current through electrodes contacted metal parts to be welded; and resistance heat is generated at the interface of metal parts and makes a nugget, resulting in melt joint. Though a large current flows, there is no danger of an electric shock because only low voltage is impressed.

5. What is the function of tungsten in TIG welding? Functions:

O2 : C2H2 = 0.85 to 0.95. Advantage

Uses a non-consumable tungsten electrode during the welding process, Uses a number of shielding gases including helium (He) and argon (Ar), Is easily applied to thin materials, Produces very high-quality, superior welds, Welds can be made with or without filler metal, Provides precise control of welding variables (i.e. heat), Welding yields low distortion, Leaves no slag or splatter.

greater case depth (case depths of greater than 0.3 inch are possible), less distortion, better impact strength. This makes it perfect for high strength and wear applications (e.g. scissors or swords). Added expense, Higher working temperatures Increased time.

Disadvantages

6. What are the specific situation where electro slag welding is used? low carbon steel plates and/or sections that are very thick. 7. What is fusion welding The metal at the joint is heated to a molten state and then it is allowed to solidify. Pressure is not applied during the welding process. (Eg) Gas, Arc welding 8. What is the minimum distance maintained between successive spot welding and why? The acceptable minimum distance is 16 times to that of thickness of metal to be welded. If the minimum distance not maintained then shunt current will flow through the already welded spot, and reduces the quality of welding. 9. Write short notes on transferred and non-transferred arc in plasma arc welding Non-transferred arc process: The arc is formed between the electrode(-) and the water cooled constricting nozzle(+). Arc plasma comes out of the nozzle as a flame. Transferred arc process: The arc is formed between the electrode(-) and the work piece(+). In other words, arc is transferred from the electrode to the work piece. 10. Write down the types of flames? i. Neutral Flame ii. Oxidizing Flameiii. Carburizing flame11. What is meant by carburizing flame? And its application? A flame that contains more acetylene than oxygen. This flame will burn at a lower temperature than the other flames, and can add extra carbon to certain welds.

12. What are the length and diameter of electrode available in market? Electrodes are available upto 12mm diameter and 450mm long. 13. What do you mean by friction welding? It is a solid state welding process wherein coalescence is formed by the heat which is obtained from mechanically induced sliding motion between rubbing surface. 14. Equation for thermit welding

15. Define the term electrode and mention its major classification. In arc welding an electrode is used to conduct current through a workpiece to fuse two pieces together. Depending upon the process, the electrode is either consumable 16. Why is flux coated on filler rods? 17. Importance of flux in arc welding. iv. Stabilizes arc. v. Reduces spattering. vi. Prevent welding seam from rapid cooling. vii. Increased deposition efficiency. Influence shape of weld bead during solidification. Adds alloying element and increases properties.

UNIT III Bulk Deformation Process

1. What is meant by recrystalization temperature?

The temperature at which destroyed grains of a crystal structure are replaced by the new strain free grains. below recrystalization temperature - cold working Above recrystalization temperature - Hot working 2. Working on the metal lead at room temperature, is considered to be hot working. Why? Recrystalization temperature of the lead is - 35C. So, The work happening in lead is above the recrystalisation temperature. So, It , is considered to be hot working. 3. Distinguish between open die forging and closed die forging. Open die process: Advantages: -simple, economical dies -useful for small quantities -wide range of sizes available -good strength Limitations: -limited to simple shapes -final machining necessary -low production rate -skilled labour required Closed die-forging (impression die forging) -in closed forging, hot metal is forced thro the cavities of die block, to take final shape

A small roll diameter is advantageous because less roll is in contact with the material, which results in a lower force and power requirement. The problem with a small roll is a reduction of stiffness, which is overcome using backup rolls. These backup rolls are larger and contact the back side of the smaller rolls. 6. Explain the principle of extrusion 7. Define extrusion as manufacturing process It is a compression forming process in which the work metal is forced to flow thro a die opening to produce desired cross sectional shape.

8. Which extrusion process requires more force- Why? Direct extrusion requires more force than indirect extrusion. complex cross-section, turbulence and Higher friction results in larger ram force 9. Define the term extrusion ratio. Extrusion ratio is defined as the starting cross-sectional area divided by the cross-sectional area of the final extrusion. 10. Difference between direct and indirect extrusion. Direct/ Forward Extrusion Indirect/ Backward Extrusion Solid ram Hollow ram Large for required for Small for extrusion process extrusion process

Advantages: -material utilization is full -better mech. properties -good dimensional accuracy -high production rate Limitations: -high cost of dies -machining is necessary 4. Classify types of extrusion i. Direct ii. Indirect iii. Hydro static iv. Impact 5. In four high roll mills, smaller diameter mills as working mills why?

Hollow parts can be made Force a

Cant make hollow objects

11. What is upset forging? Upset forging increases the diameter of the workpiece by compressing its length. 12. Mention different types of shape rolling operation.

Blooming rolls Edging rolls Ring Rolling Thread Rolling

13. List out any four parts manufactured using shape rolling operation

I beams, channels, railroad, screws and seamless ring.

14. What is sejournet process? The extrusion process which is based both on the use of a lubricant in a viscous condition at extrusion temperature and on a separation between the lubrication of the chamber wall and that of the die is called sejournet process.

Limitations : high temp. results oxidation of surface tooling & handling costs are high intricate shapes (as in castings) are not possible 19. Classify types of forging machine Forging Presses Forging Hammers -Hydraulic press -Gravity drop hammer -Mechanical Press -Power drop hammer -Screw press -Counter drop hammer -Helve Hammers - Trip Hammers - Level spring 20. What is ironing Ironing is a sheet metal forming form process that uniformly thins the workpiece in a specific area.

15. What is skew rolling? The rolls are powered and nd the job is in due to frictional force between metal and roll surface. The torque is on the rolls is being zero.

What is fullering 21. Fullering is a similar process that thins out sections of the forging using a convex shaped die.

UNIT IV SHEET METAL PROCESSES

1. What is spring back effort and how it is recovered? Spring back is defined as the movement of the metal to resume its original position causing a decrease in bent angle. After the applied force is withdrawn. It can be avoided by, Over stretching using V-type blocks Coining the edges. 2. What is peen forming and what are its applications In n this process, a mechanical impact is produced by steel balls which are accelerated to a specific velocity and directed in a desired pattern. Application:- Specific portion of crank shaft, connecting road and gears. To produce honeycomb panels like aircraft wings. 3. What is punching operations Punching is a process in which the punch removes a portion of material from the larger piece or a strip of sheet metal. m 4. Give the differences between punching and blanking. blanking

16. Why are a number of processes required to roll a steel bar? To reduce the thickness to a greater level multiple rolling process are used. And to get the desired shape its passed through multiple rollers. 17. How are seamless tubes produced? Seamless tubes are manufactured by pierce rolling method. Round ound billets up to the plastic stage of steel and piercing in a Cross Roll Piercer. 18. What are advantage and disadvantage of forging Advantages: products have structural uctural homogeneity no porosity, blow holes, voids metal grains are refined better mechanical properties better machining qualities, minimum metal removal required relatively smooth surfaced products close dimensional tolerances rapid duplication of products

If the small removed piece is discarded, the operation is called punching, whereas if the small removed piece is the useful part and the rest is scrap, the operation is called blanking

5. What is super plastic forming operation Very fine grains are obtained within certain temperature ranges & at low strain rates. These alloys can be formed into complex shapes by super plastic forming. Zinc, Aluminum and Titanium has super plastic behavior. 6. What are the advantages of rubber pad forming process?

This is a process of making raised or projected design on the surface of the metal with its corresponding relief on other side. Combination of drawing and bending 16. What is lancing operation that is done on sheet metals? A shearing operation that cuts an interior section of the metal without removing the section. A lancing operation leaves an opened metal tab.

7.

List any four components manufactured using drawing method Wires, Tubes, to make hydraulic systems and to get rectangular, hexagonal and square shapes. 8. What are the common explosives used in explosive forming method

9. Define the term formability The capability of sheet metal to be deformed into desired shape is called formability. 10. What do you mean by minimum bend radius? While bending outer surface in tension and inner surface is in compression. The minimum radius to which the material can be bent known as minimum bend radius 11. Explain piercing operation It is a process by which a hole is cut (or torn) in metal. It is different from punching in that piercing does not generate a slug. Instead, the metal is pushed back to form a jagged flange on the back side of the hole. A pierced hole looks somewhat like a bullet hole in a sheet of metal. 12. Why it is necessary to provide proper clearance between the punch and die in a shearing operation? It allows fracture to meet when break occurs. It depends on type of material, Thickness of material, Hardness of material and type of operation. 13. Advantage of hydro forming technique Deeper draws are obtained, compared to other methods. It is due to the pressure around the rubber membrane forces the cup against the punch. 14. What is limiting drawing ratio. The volume of material removed from the work per unit volume of wear is known as drawing ratio. 15. Define embossing

Notching- A shearing operation that removes a section from the outer edge of the metal strip or part. Perforating is a piercing operation that involves punching a large number of closely spaced holes Fine blanking is a specialized form of blanking where there is no fracture zone when shearing. This is achieved by compressing the whole part and then an upper and lower punch extract the blank.This allows the process to hold very tight tolerances, and perhaps eliminate secondary operations.

UNIT V MANUFACTURING OF PLASTIC COMPONENTS

1. Write the difference between thermo plastic and thermo setting plastic. Thermo plastic Thermo setting plastic It softens by heating It cannot be soften by heating Linear chain polymer Cross linked polymer Structure Additional Polymerization Condensation Production polymerization Softer and less strong Harder and stronger It can be remoulded Cannot remould. 2. Plastic strips are to be converted into 3D objects. Suggest one process and explain 3. What are the characteristics of thermo forming Thermoforming process is a process in which a flat thermoplastic sheet is heated & deformed into the desired shape.

Polymerization is a process of reacting monomer molecules together in a chemical reaction to form polymer chains. degree of polymerization is usually defined as the number of monomeric units in a polymer 4. Describe briefly about thin flim blowing Blown film extrusion is a technology that is the most common method to make plastic films, especially for the packaging industry. The process involves extruding a tube of molten polymer through a die and inflating to several times its initial diameter to form a thin film bubble. This bubble is then collapsed and used as a l lay-flat film or can be made into bags. 8. Plastic milk bottle is thermo plastic or thermo setting plastic? How could you find out? Thermoplastics softens while heating it. Its less brittle, bri soluble in organic solvent. thermo setting plastics are more brittle and insoluble in organic solvents and more brittle and insoluble in organic solvents. 9. Adhesives used for bonding of plastics Epoxy, urethane, cyano-acrylic, acrylic, silicone 10. Why screw injection ection moulding machine is is better than ram type injection moulding machine?

In screw injection moulding machine pellets are fed into the hopper, the resins are pushed along with the heated reciprocating screw. In ram type pellets cant be used.
11. What is parison? It is the molten tubular form made on an Extrusion Blow Molding machine by extruding thermo plastic resins. This viscous melt resin called Parison is put into two halves of Blow Molds and shaped to the form of cavity of mould by blowing compressed compress air. 5. Listout materials for processing plastics Additives: 1. Plasticizer - improve plastic behavior. 2. Calalyst - fastup the process 3. Dyes and pigments colour 4. Initiators - initiate the reaction. 5. Modifiers - improve mechanical cal property 6. Lubricants - to reduce friction 7. Flame retardents to enhance non- inflammability 8. Solvents - to dissolve fillers and plasticizer 9. Elastomers - to enhance elastic property 10. Stabilizer - To retard degradation Fillers economises the quamntity 1. Mica 2. Cloth fibre 3. Asbestors . 6. What are the advantages of transfer moulding In n this process, thermosetting resin is heated in a separate chamber & then the softened polymer is forced into a heated mould, where curing occurs. 7. What is degree of polymerization

12. Calendering process It is a process in which a hot mass of polymer is fashioned into a continuous sheet by passage through a system of heated rolls that is a calender. The sheet is then cooled and wound up into rolls.