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University of Engineering and Technology, Taxila

Mechanical Engineering Department

Manufacturing Processes 1

Note: Attempt Paper according to the given order. (Strictly) Part A) Give to the point answer to the following questions; (Welding) 2*10=20 1. Differentiate between machine, automatic and robotic welding. 2. What are the five basic types of joints? Draw figures. 3. Differentiate between spot weld and seam weld. Draw figures. 4. What is meant by the term faying surfaces? 5. Why is it desirable to use energy source for welding which has high heat density? 6. Define arc shielding and flux in welding processes? Give examples. 7. Differentiate between SMAW and GMAW? Draw figures. 8. Why is the shielded metal arc welding process difficult to automate? 9. Describe cross wire welding process? 10. What are factors that affect the weld ability? ------------------------------------------------------------------------------------------------------------------------------------------------------------------------Part B) Give to the point answer to the following questions; (Casting) 2*10=20 1. What is draft and why is it used? 2. What is cold shut and what causes it to form? 3. What are two stages of solidification and what occurs in them? 4. Define top, side, live, dead, blind, open risers? 5. Are metal casting used in passengers cars and light trucks? What extent? 6. What is a casting process and green sand? 7. Describe types of patterns. 8. Describe some of the process advantages of permanent mold casting. 9. What are the key differences between true centrifugal, semi centrifugal casting and centrifuging? 10. How does the air in the mold cavity in die casting escape? ------------------------------------------------------------------------------------------------------------------------------------------------------------------------Part C) Give to the point answer to the following questions; (Powder metallurgy, Bulk deformation) 2*10=20 1. What are limitations associated with PM processing? 2. Define mesh count and packing factor. 3. Draw figures of several atomization processes to produce metallic powders. 4. Why a controlled atmosphere furnace is desirable in sintering process? 5. Why is PM technology so suited to produce gears and bearings? 6. What is forging and isothermal forging? 7. Name different types of rolling mills. 8. What is a draft in a rolling operation? 9. Why is friction a factor in in determining the ram force in direct extrusion but not a factor in indirect extrusion? 10. What is sticking in a hot rolling operation? ------------------------------------------------------------------------------------------------------------------------------------------------------------------------Part D) A drawing operation is used to form a cylindrical cup with inside diameter = 75mm and height = 50 mm. The starting blank size = 138mm and the stock thickness = 2.4mm. Based on these data, is the operation feasible? Find Drawing force and holding force and also define all the terms and parameters which are being involved in solution. Also give additional comment if you know about all these parameters. (Sheet metal working) 2*2*2*2*2 = 10 ------------------------------------------------------------------------------------------------------------------------------------------------------------------------Part E) Write the project report which you have done with this subject in this semester. Include the introduction, Explanation, Methods/Findings, Suggestions, conclusion and whatever which is linked with it. (Semester project) 10 -------------------------------------------------------------------------------------------------------------------------------------------------------------------------