Code No: RR312402

Set No.1

III B.Tech. I Semester Supplementary Examinations, February -2007 PRODUCTION TECHNOLOGY (Automobile Engineering) Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks

1. (a) Explain the advantages of casting over other manufacturing processes. (b) How can a sweep-type pattern cast a solid vase shaped casting? (c) How does moisture in molding sand affect a wood pattern and core? [5+6+5] 2. (a) With the help of a sketch show the parts of a cupola. State its advantages and limitation. (b) Explain how you will use a sieve shaker for determining the grain fineness of foundry sand. [10+6] 3. (a) What is centrifugal casting? Discuss any one type of centrifugal casting with the help of neat sketch. (b) Describe the following: i. Side blind riser ii. Swirl gate. 4. (a) Describe the following types of welding techniques: i. MIG welding ii. Explosive welding. (b) Compare upset welding and spot welding process? [8+10+6] [8+8]

5. (a) With the help of a schematic diagram explain the constructional details and reactions involved in Oxy-acetylene welding. (b) Differentiate between “Solid Phase Welding” and “Liquid Phase Welding”. [8+8] 6. (a) Explain the causes for different types of cracks in welds. (b) Estimate the standard time for cutting strips of 6m long by using manual oxy-acetylene torch from plates of i. 20mm and ii. 50mm thick. (c) Describe the dip soldering metal joining technique. 7. (a) Show by sketch the various roll arrangements used in rolling mills. (b) Explain the various zones and their functions in the design of a drawing die. (c) What is tube sinking? Explain. 1 of 2 [6+5+5] [5+6+5]

Code No: RR312402

Set No.1

8. (a) Explain why cold extrusion has become an important manufacturing process. (b) Describe roll forging and its principal uses. (c) What is meant by press forging. How does it differ from drop forging? [5+5+6]

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Code No: RR312402

Set No.2

III B.Tech. I Semester Supplementary Examinations, February -2007 PRODUCTION TECHNOLOGY (Automobile Engineering) Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks

1. (a) Explain using simple sketches the procedure for making green- sand moulds. (b) How does clay content affect molding, sand strength and permeability? (c) Is an allowance made for draft in a disposable mould casting? [6+5+5]

2. (a) Why testing of foundry sand is necessary? What are the common tests performed on Foundry sand? (b) Describe the process of shell molding and explain the advantages and limitations. [8+8] 3. (a) How are gates and risers removed? (b) Why pouring basin is required in gating system? Discuss different types of Pouring basins. [8+8] 4. (a) Classify the different regions of Oxy-acetylene flame and with the help of neat sketches explain their characteristics. (b) What is “Weldability”? Explain how and on what basis weldability can be assessed? [10+6] 5. (a) Compare TIG welding with MIG welding with regard to equipment, performance, merits and demerits. (b) Explain the various steps involved in flash butt joint welding process. [8+8] 6. (a) How is Brazing different from soldering? Compare them with regard to methods adopted and their applications. (b) Estimate the standard time for cutting strips of 8m long by using manual oxy-acetylene torch from plates of i. 18mm and ii. 10mm thick. 7. (a) Define hot working and cold working of metals. (b) What are the advantages and limitations of hot working? (c) Explain tube drawing with a movable mandrel. 8. (a) Explain briefly about the following: i. Impact extrusion ii. Hydrostatic extrusion 1 of 2 [5+5+6] [10+6]

Code No: RR312402

Set No.2
[6+5+5]

(b) Why is intermediate shape important in forging operations? (c) Explain the various steps involved in drop forging.

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Code No: RR312402

Set No.3

III B.Tech. I Semester Supplementary Examinations, February -2007 PRODUCTION TECHNOLOGY (Automobile Engineering) Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks

1. (a) Explain the following terms: i. Pattern allowances ii. Color codes for patterns (b) Why is coarser sand better for steel castings than fine grained sand? Why is it that as castings increase in size, it is often better to use increasingly coarser sand? [8+8] 2. (a) Explain the following: i. AFS Clay content test ii. AFS Sieve Analysis. (b) Describe working of cupola with its construction and different temperature zones. [8+8] 3. (a) Why is pouring temperature important in casting process? State and explain various pouring equipments. (b) Explain investment-casting process. 4. (a) Explain the mechanical effects of Welding Heat. (b) What is flux generally used in gas welding? What characteristics are required for a flux? [8+8] 5. (a) Explain the various types of resistance welding processes. What are the advantages and disadvantages and their limitations? (b) Explain the advantages and disadvantages of laser beam welding. [10+6] [8+8]

6. (a) What are the various welding defects? Discuss the causes for these defects. (b) Estimate the standard time for cutting strips of 10m long by using manual oxy-acetylene torch from plates of i. 15mm and ii. 30mm thick. (c) Explain the torch brazing type of metal joining technique. 7. (a) What are the advantages and disadvantages of cold working? (b) Explain briefly the theory of rolling. (c) Why is it necessary to provide proper clearance between the punch and the die in a shearing operation? Give reasons. [5+6+5] 1 of 2 [5+6+5]

Code No: RR312402

Set No.3
[5+5+6]

8. (a) What are the different forging defects? Explain them briefly. (b) Compare forward and backward extrusion processes . (c) Explain swaging process with a suitable sketch.

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Code No: RR312402

Set No.4

III B.Tech. I Semester Supplementary Examinations, February -2007 PRODUCTION TECHNOLOGY (Automobile Engineering) Time: 3 hours Max Marks: 80 Answer any FIVE Questions All Questions carry equal marks

1. (a) Explain the importance of using metal as pattern material. (b) Discuss the sand constituents and the desired properties for Molding sands and core sands. [8+8] 2. (a) With a neat sketch explain the operation of a cupola, its charge composition and control of the melt composition. (b) Briefly explain the pressure die casting process and its characteristics features. [8+8] 3. (a) How are gates and risers removed? Explain briefly. (b) Explain the different types of gates. Draw the simple sketches. 4. (a) Explain the phenomenon of “Residual Stress” and “Distortion”? (b) Explain how Oxy-acetylene torch can be used for both Welding process. [8+8] 5. (a) Describe the following types of welding techniques: i. Friction welding ii. Laser Beam Welding. (b) With the help of a neat sketch explain the principle of Spot welding? [10+6] 6. (a) Explain the causes for different types of cracks in welds. (b) Estimate the standard time for cutting strips of 5m long by using manual oxy-acetylene torch from plates of i. 22mm and ii. 8mm thick. (c) Describe the braze welding type of metal joining technique. 7. (a) What is the difference between hot rolling and cold rolling? (b) Sketch and explain how seamless tubes are manufactured. (c) Explain with a neat sketch the process of rotary forging. [5+6+5] 8. (a) Explain hot extrusion and cold extrusion processes with suitable sketches. (b) Explain the difference between open-die and impression-die forging. (c) What are the main considerations in designing a forging? State and explain. [5+5+6] [5+6+5] [8+8]

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