Code No: 311401 III B.Tech. I-Semester Regular Examinations, November-2003. MANUFACTURING TECHNOLOGY (Mechatronics) Max.

Marks: 80

Set No.

1

Time: 3 hours

1.a) b) c) 2.a) b) c) 3.a) b) c) 4.a) b) c) 5.a) b) c) 6.a) b) c) 7.a) b) c)

Answer any FIVE questions All questions carry equal marks ---Why is sand widely used for mould working? Discuss the principal parts of the moulding sand. What are the different materials used for pattern making? Explain clearly the advantages of each. What factors affect the green permeability, green strength and dry strength of a sand and how? What are the characteristics of good core? Explain briefly. List the defects of casting and corresponding remedies. Discuss with the help of simple sketch, the die casting process. Discuss the relative merits and demerits of TIG and MIG welding. Describe with a neat sketch the gas welding process. What are the advantages and limitations of Laser welding. What are effect of cold working? How are rolling mills classified? Draw the various rolling mill arrangements. Briefly discuss the following: i) Notching ii) Parting iii) Slitting Explain briefly the various press working operations with suitable sketches. Briefly discuss the manufacturing methods for making pipes and tubes. Distinguish between various extrusion processes. Discuss briefly the advantages and disadvantages of mechanical and hydraulic presser. Explain in detail some of the typical forging defects. State the differences between ‘smithing’ and ‘forging’. Give a list of smithy operations. Explain the term basic size and nominal size. Sketch a dial indicator and explain its working mechanism. Discuss the following: i) Snap gauges. ii) Thread gauges.

(Contd…2)

Code No:311401 8.a) b) c)

:: 2 ::

Set No.1

Discuss the method to measure the surface roughness. What are slip gauges? What are their uses? Describe a method to measure the effective pitch diameter of a screw plug gauge. -*-*-*-

Code No: 311401 III B.Tech. I-Semester Regular Examinations, November-2003. MANUFACTURING TECHNOLOGY (Mechatronics) Max. Marks: 80

Set No.

2

Time: 3 hours

1.a) b) c) 2.a) b) c) 3.a) b) c) 4.a) b) c) 5.a) b) c) 6.a) b) c) 7.a) b) c)

Answer any FIVE questions All questions carry equal marks ---Name the various types of patterns used in casting practice and explain them briefly. What are the green permeability, green strength and dry strength of moulding. Briefly discuss the various methods moulding. Enumerate the various casting defects and suggest suitable remedies. What are the merits and demerits crucible melting. State the differences between true centrifugal casting, semi-centrifugal casting and centrifuging. Which method is used for cast iron pipe production? Why? Explain the principle of friction welding. Explain how straight and reverse polarity affect the weld penetration. With the help of neat sketch, explain the principle of spot welding. Define recrystallisation temperature. What is the significance of temperature in metal working? What are the advantages of rolling processes? Briefly discuss the following: (i) Blanking (ii) Coining Define extrusion and how does it differ from forging. Explain the wire drawing process. Explain how seamless pipes are produced by extrusion. Draw the power press and name the parts. Name the various heating equipments used in forging process. Explain their functions. Briefly discuss about Roll forging operation. Clearly distinguish between clearance and allowance Discuss the constructional details of a mechanical comparator Briefly discuss the following: i) Optical flats ii) Straight edges. (Contd…2)

Code No:311401 8.a) b) c)

:: 2 ::

Set No.2

What is Taylors principle as applied to design of limit gauges? What is bevel protractor? How it is used for precision angular measurement? Draw the neat sketches of the following limit gauges: i) Plug gauges. ii) Ring gauges. -*-*-*-

Code No: 311401 III B.Tech. I-Semester Regular Examinations, November-2003. MANUFACTURING TECHNOLOGY (Mechatronics) Max. Marks: 80

Set No.

3

Time: 3 hours

1.a) b) c) 2.a) b) c) 3.a) b) c) 4.a) b) c) 5.a) b) c) 6.a) b) c) 7.a) b) c)

Answer any FIVE questions All questions carry equal marks ---Explain the process of core making. Name the various casting defects and give an account of their initiation and causes to eliminate them. Draw a typical mould and name its principal parts. Discuss the factors to be considered in the choice of metal melting furnaces. State the advantages and disadvantages of centrifugal casting. Briefly discuss about machine moulding process. Discuss the common welding defects and remedies for them. Describe with a neat sketch the laser beam welding. Explain how the different types of flames in welding torch are obtained. State some of their applications. Distinguish between hot working and cold working of metals. Discuss the principle of piercing . Explain the following terms: (i) Trimming (ii) Shaving (iii) Nibbling. Explain the press working processes. Explain the principle of impact extrusion with the help of a neat sketch. Discuss the rolling process and draw the typical shapes of the parts that are produced by rolling process. Explain the process of drop forging. Explain the following hand forging tools: i) Anvil ii) Fullers and flatters iii) Punches and drifts iv) Swage block What are the main advantages of forging over casting or welded parts. Classify the different types of fits. How the internal angles of dovetails are measured accurately? Explain. What are advantages of the limit gauges? Discuss. (Contd…2)

Code No:311401 8.a) b) c)

:: 2 ::

Set No.3

Draw and explain the working of sigma mechanical comparator. Distinguish between ‘line standards’ and ‘end standards’. Describe the following: i) Optical flat ii) Surface gauge. -*-*-*-

Code No: 311401 III B.Tech. I-Semester Regular Examinations, November-2003. MANUFACTURING TECHNOLOGY (Mechatronics) Max. Marks: 80 Answer any FIVE questions All questions carry equal marks ---1.a) b) c) 2.a) b) c) 3.a) b) c) 4.a) b) c) 5.a) b) c) 6.a) b) c) 7.a) b) c)

Set No.

4

Time: 3 hours

What is the difference between dry sand moulds and green sand moulds? State some of the advantages and disadvantages of each. Discuss the various allowances provided on the patterns. Explain the defects in casting with their reasons. Describe the operation of a cupola furnace for metal casting. What is centrifugal casting? Briefly discuss the process. What is permanent mould casting? Discuss its advantages and disadvantages. Briefly explain the process of carbon arc welding. Describe with the help of a neat sketch the principle of thermit welding . State the purpose of thermit welding. Where would you recommend it and why. Discuss the advantages and limitations of cold working. Briefly describe the forming method of wire drawing. Explain the following: (i) Punching (ii) Embossing (iii) Blanking. With a simple sketch explain the different methods of extrusion. Compare the hot rolling and cold rolling. Describe the stretch forming process with a sketch. Explain the following forging operation: i) Upsetting ii) Swagging iii) Forge welding. What is press forging and how does it differ from drop forging? Explain. Explain the various forging hammers the forging used in process. What are the uses of gauge-blocks. State the various types of fits used in assembly operation. Sketch and describe the method of measuring a taper plug gauge using rollers, balls and slip gauges. (Contd…2)

Code No:311401 8.a) b) c)

:: 2 ::

Set No.4

Explain briefly the principle and working of optical collimator. Describe mechanical comparator and clearly explain the magnification method adopted in it. Explain the following terms: i) Outer diameter ii) Thread profile. iii) Effective diameter. -*-*-*-