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Important questions for basic manufacturing processes

*Highlighted questions are most important

Unit 1 Engineering materials and mechanical properties


Explain various mechanical properties with suitable diagramStrength, elasticity, plasticity, stiffness, malleability, ductility, brittleness, toughness, hardness,
resilience, hardness, machineability, formability, weldability, fracture fatigue & creep.
Stress strain diagram for ductile and brittle materials.
Explain how Carbon steels are classified based on percentage of carbon (low carbon steel, mild steel,
medium carbon steel & high carbon steel) their properties & applications.
What is cast iron and explain various types of cast iron?( grey cast iron, white cast iron,
malleable cast iron and nodular cast iron)
What is brass (alloy of copper and zinc) , bronze and explain various types of brasses, brasses
their composition, properties and applications?

Unit 2 Metal forming , their applications and casting process





Explain six differences between hot working and cold working?

What is forging and explain various types of forging processes (open die forging, impression die
forging).What is difference between wire drawing and tube drawing?
What is difference between rolling and extrusion and explain various types of extrusion processes
(direct extrusion and indirect extrusion)? List various types of rolling mills(.( single pass rolling
mill, double pass rolling mill, cluster rolling mill)
Explain any six patterns with neat sketches?( soild pattern, split pattern, multipiece pattern, sweep
pattern, gated pattern, segmental pattern) and explain any three pattern allowances.
shrinkage allowance, machining allowance, draft allowance, rapping allowance, distortion allowance)
Explain the process of mould making with neat sketch? Explain any six moulding sand
properties( Refractoriness, permeability, green sand strength, good flowability, good
collapsibility, cohesiveness, adhesiveness)
Explain the Gating system with neat sketch(pouring basin, gate, runner and riser) or various
components of mould with neat sketch. Explain any six casting defects and list their causes.(blow
holes, shrinkage cavity, misrun, cold shut, mismatch, drop, scab ,hot tear)

Unit 3 Machining operations and Welding operations





Explain different parts of lathe machine( bed, headstock, tailstock, carriage- apron, saddle, cross
slide, compound rest, tool post) with neat sketch of lathe machine? Explain any four operations
performed on the lathe machine with neat sketches( turning, taper turning, drilling, boring,
knurling,threading, forming, parting and grooving)?
What is shaper and explain its different parts( bed, column, ram, tool head, cross rail, table, vice)
with neat sketch of shaper machine? Explain differences between shaper and planer machine?
What is milling machine, difference between up milling and down milling with neat sketch?
Also explain its different parts with neat sketch of milling machine? Explain any four operations
performed on the milling machine ( plain milling, face milling, angular milling, form milling, straddle
milling, gang milling) with neat sketches?
What is welding? Explain how you classify the welding processes ( fusion or non pressure welding and
plastic or pressure welding)? List various types of welding processes( fusion welding- arc welding, gas
welding, pressure or plastic welding- resistance welding)
Explain arc welding with sketch, its principle? Explain various electrodes that are used in
welding ( consumable electrodes and non consumable electrodes)? Why electrodes are coated,
give reasons( to prevent from oxidation and to remove impurities by forming slag)?




Write about the importance of fluxes being used in welding. ( to prevent from oxidation and to remove
impurities by forming slag)?
What is resistance welding and what is its working principle ( H= I 2 R T , I current supply, R =
resistance at contact point and T- time of flowing current)with some applications? Explain dthree
types of resistance welding process with neat sketches (spot welding, seam welding , butt welding
and projection welding)?
What is gas welding, gas welding equipment ( gas cylinders- oxygen and acetylene gases, hose
pipe, torch, pressure gauge, regulator)Explain various types of gas flames with labelled diagram,
used in gas welding? Give their applications also( neutral gas flame- in this oxygen and acetylene
gas percentages are equal, oxidising flame- in this percentage of oxygen is more as compared to
acetylene and reducing flame- in this percentage of acetylene is more as compared to oxygen)
What are five differences between soldering, brazing and welding? ( soldering carry out below
450 degree Celsius and use of solder which is alloy of lead and tin, brazing is carried out above
450 degree Celsius and use of filler metal known as spelter- alloy of copper, zinc and silver)

Unit 4 Miscellaneous topics





What is the purpose or objectives of heat treatment process (to relieve internal stresses, to improve
mechanical properties, to refine grain structure)? Draw iron carbon diagram.
Explain following heat treatment processes- Annealing, Normalising, Hardening and tempering
and case hardening or surface hardening.( in annealing after heating cooling in furnace, in
normalising heating and then cooling in air, in hardening heating and then cooling in water)
In case hardening only the hardness of surface is increased by diffusing carbon with heating in carbon
atmosphere to change outer surface microstructure only while the core microstructure is remains same.
What is plant layout , its objectives and advantages of good plant layout? Explain various types
of plant layout (product or line layout, process or functional layout, combination or group layout
and fixed position layout).
What is composite, ceramics, plastic, rubber and cement concrete, their properties, and applications and
give some examples? Explain any three plastic making processes( injection moulding, compression
moulding and blow moulding)
Explain the differences between galvanisation (process of coating of zinc on steel articles to
increase corrosion resistance) and electroplating (coating of different metals like gold, tin, lead,
etc. to increase life of metallic components) process with neat sketches?