IPE331

LATHE MACHINE
1.Discussthefunctionsofthefollowingcomponentsduringturningoperationandidentify
correspondingposition/locationofthe
a.crossslide
b.Topslide
c.HalfNut
d.ChangeGear
e.Swivelplate
f.Apron
2.Discussthetwofeedmethodandtapperturningattachmentmethodforthetapperturningin
thelatheoperation
3.Whatarethedifferencebetweenturningandthreadingoperation.
4."Turningisamicrothreadingprocess"justifythestatement.
5.Howtapperboringisdoneinlathemachine?
6.Howisthesizeofthelathemachineisdesignated?Sketchthedifferenttypesofsurfacesthat
canbegeneratedbyturningoperation.
7.Whatarethemainclassesofturningoperationsandwriteappropiateclassesofthefollowing
latheoperations:
a.tapperboring
b.Knurlingoflongworkpiece
c.Straightturningofshortworkpiece
d.tapperturning.
e.Internalthreading.
8.Isthechuckanintegralpartofthelathe?Describetheoperatingmechanismofauniversalor
scrollchuckduringgrippingoftheregularshapedworkpiece.

9.Describebrieflyhowcolletsanddogsoperatedinholdingaworkpieceinalathemachine.
10.Describedifferenttypesoftapperturninginlathemachine.

MILLINGMACHINE
1.Explainupmillinganddownmilling.Whatarethedifferences?
2.Discussthefollowingmillingoperationswithnecessarysketches.Showthedirectionoffeed
andhowwouldyouliketoprovidethefeed:
a.Facemilling
2.Verticalmilling
c.angleordovetailmilling.
3.Describegearcuttingprocesses.
4.Whataretheimportanceofdividinghead?Whatarethepurposeofindexplateandindex
crankpininthedividinghead?
5.Describegeargeneratingprocess.
6.Howtimeforfacemillingandplainmillingiscalculated?Considerbothroughcutandfinishing
cut.
SHAPERANDPLANERMACHINE
1.Describethequickreturnmechanismforshapermachine.
2.Differentiatebetweenshapermachineandplanermachine.
3.Whatarethewaysofsettingacuttingtoolinangularpositioninashapermachine?
4.Whatisstrainbackeffect?Howdoesiteffecttheshapingprocess?

5.Describethemechanismofclapperboxduringtheshaping/planingprocess.

FORMING
1.Withneatsketches,describethetypeofmetalflowthatoccursinextrusion.
2.Explainwhycoldextrusionhasbecomeanimportantmanufacturingprocess.Listthe
advantagesanddisadvantagesofextrusionprocess.
3.Whattypeofdefectmayoccurinextrusionandindrawingprocess?Explainitscause.
4.Describedoubleandtripleaction.
5.Describeextrusionprocess.Howdoesitdiffersfromrollingandforgingprocess?
6.Describedeepdrawingprocess.
7.Whataretheprocessesusedforcontrollingtheinternaldiameterinthetubedrawing?
8.Definepressworking.Withnecessarydiagram,describeacompound,combinationand
progressivedie.
9.Withneatsketches,describethedifferenttypesofopenframepress.
10.Whatareknucklejointandtoggleprocessandwhatisthepurposeofeach?
11.Brieflydescribetheformingofsheetmetal.Howtheprocessesareclassified?
12.Brieflydescribethefollowingpressoperations:
a.Shaving
b.Blanking
c.Lancing
d.Cutoff

13.Defineextrusionratioandgiveitscommonvalueforvariousmetals.Listtheadvantagesand
disadvantagesofextrusionprocess.

14.ExplainthebendingtechnologyComparetheopenandclosedframepresses.
15.Withablockdiagram,giveanoutlineoftheforgingoperation.Identifythereasonsforthe
barrelingeffectintheopendieforging.Howcanyoureducethiseffect?
16.Drawthesketchesfortwohighandthreehighrolls.Statewhyandhowyouwillreducethe
rollingforce.
17.Withnecessarysketchesdiscusstheprogressivepiercingandblankingdieformakinga
washer.

18.Itispossibletoreducethethicknessbysimplestretching.Woulditbeafeasibleprocess?
19.Whyitisnecessarytoestimatetheforgingforce?Explainwhythecontrolofthevolumeof
theblankisimportantinclosedieforging.
20.Discusswhyextrusionisabatchorsemicontinuousprocess?Doyouthinkitcanbemade
intoacontinuousprocess?
GRINDING
1.Discusstheimportanceofthepackingdensityoftheabrasiveparticleingrindingwheel.
2.Discussthehorning,lapping,buffingprocessofthesurfacefinishing.
3.Howdoessuperfinishingprocessdiffersfromthehorningprocessofpricisionfinishing
process?
4.Whatarethedesiredpropertiesofthegrindingwheel?
5.Whatdoyouunderstandbygritsize80ofSiCabrasive?
6.Whatarethedifferencesbetweentheprecisionandnonprecisionsurfacefinish?
7.Mentiontheprincipleabrasivematerials,theirtradenamesandtheirproperties.
8.Whatdoyouunderstandbythe"grade"and"structure"ofagrindingwheel?

9.Classifythegrindingprocessanddescribethecenterlessgrindingoperationwithneat
sketches.
10.Whatarethefactorsonwhichtheperformanceofthegrindingwheeldepends?

WELDING
1.Defineweldebility.Withneatsketchesdescribethefollowingweldingprocesses:
a.Projectionwelding
b.Flushbuttwelding
c.Electronbeamwelding
d.Thermitwelding
e.Submergedwelding
f.Arcwelding
g.Seamwelding
h.Gasmetalwelding

2.Fromproductionviewpointwhataretheattractivecharacteristicsof
a.LaserBeamwelding
b.Percussionwelding
c.Submergedwelding
3.Enumeratethedefectsencounteredwithweldedproductsandsuggestmethodstocounter
thosedefects.
4.Whatarethefluxesusedinthebrazingmethod.Writedowntheadvantagesand
disadvantagesofbrazingprocess.
5.Differentiatebetweenconsumableandnonconsumableelectrode.Forwhichprocessafiller
metalhastobeaddedbyaseparatemechanism.
6.Differentiatebetweensoldering,brazingandwelding.
7.WhataretheinertgasesusedinTIGandcomparethereproperties.
8.Differentiatebetweenseamweldingandspotwelding.
9.Whatarethecommonusesofthebrazingprocess?

10.Howweldingprocessisclassified?Differentiatebetweenautogeneous,homogeneousand
heterogeneousweldingprocess.
11.WhatmetalscanbejoinedbyMIGweldingprocess?Whatarethesomeofthemost
importantadvantagesgainedbythisweldingprocess?
12.Differentiatebetweenwelding,rivitingandcastingprocesses.
13.DescribeTIG.Howcanyouincreasethedepositingrateoffillermetal?
14.Distinguishbetweenstraightandreversepolarity.
15.Whydoyouuseshieldinginarcwelding?Howshieldingisdoneandhowitmayaffectthe
weldifnotproperlycontrolled?
16.Writedowntheprincipleofresistancewelding.
CASTING
1.Withneatsketchdescribedifferenttypesofcastingdefectandtheirremedy.
2.WhatarethecriteriaforselectingInvestmentCastingoverplastermoldcasting?
3.Explainimportantfactorsincastingprocess.
4.Writedownimportantconsiderationingatingsystemsanddescribedifferenttypesofgatein
castingprocess.
5.Writedownthetheadvantagesofdiecasting.
6.Describeinvestmentcasting.
7.Whypatterndimensionsandshapeareimportantforaccuracyandnondefectiveproduct?
8.Whycoreismadeforsandcasting?
9.Whywoodpatternsarenotusuallypreferredformassproductioninsandcasting?

10.Whataretheimportantfactorsthatyouhavetoconsiderduringselectingsandforsand
casting?
11.Brieflydiscusstheingredientsofmoldingsand.Whatarethemaincharacteristicsofcore
sandandmoldingsand?
12.Describehotchamberedandcoldchambereddiecasting.
13.Describecentrifugalcastinganditsadvantages.
14.Discussthedifferencebetweentheexpandableandpermanentmolds.
15.Listtheconsiderationsforselectingthepatternmaterials.Explainwhyacastingmayhavea
slightlydifferentsizeandshapethanthepatternusedtomakethemold.
16.Discussthedesignapproachforexpandablemoldcastinginthecontextofcorners,angles,
sectionthickness.Drawnecessarysketches.
17.Describeinjectionmolding.
18.Whyhotmoldsarenotopeneduntiltheplasticproductinsidethemoldcoolssufficiently?
19.Nametheallowancesthatareconsideredduringmakingapattern.
20.Whatdoyouunderstandbyhotspotonthecasting?Howwillyoueliminatecavitiesinthe
hotspot?

TOOLGEOMETRY
1.Namethesystemsofdesignatingcuttingtools.SketchasinglepointcuttingtoolunderASA
andORSsystem.Definevarioustoolangles.
2.Derive
a. =e (/2-c)
b. tan m =( tan2o + tan2 )
c. cot y = cot 0 cos + tan sin

d. o = tan-1 (cos o / ( - sin o))

e. cot x = cot 0 sin - tan cos
f. tan y = tan 0 cos + tan sin
g. = tan-1 ( tan o / cos )
3.Name the factors that contributes to the formation of different types of chips.
4.Enumerate essential requirements of a tool material. Name various cutting tool
materials.
5.Discussed different types of chips formed during metal machining.
6.Write down the condition for developing continuous chip with BUE.
7. With the help of sketch describe machining process.
8. Discuss ultrasonic machining process.
DRILLING
1.Sketch detail of a drill tool and show different angles as well. Why body diameter
clearance is important?
2. What are the differences among the drilling, boring and reaming operations?
3. Describe briefly the hole broaching operation.
4.Describe main differences and similarities of the following machining operations:
a. Drilling
b. core drilling
c. Step drilling
d. Boring
e. Counter Boring
f. Counter sinking
CERAMICS AND GLASS MANUFACTURING
1.What are the additives used in ceramic manufacturing? Discuss their purpose.
2.Discuss the following manufacturing process of glass product:
a. Tube and Rod
b. Sagging for discrete product
c. Bottle.
3.Discuss the slip casting, Extrusion and Jiggering processes of ceramic product
manufacturing.

4.How do you increase the strength of a glass product?

5.Why controlled atmosphere is needed in dying process of ceramic product
manufacturing? How do you control it?
6. Write down the processing steps involved in ceramic manufacturing.
7.Why is the drying process is said to be the critical stage in ceramic
manufacturing?
8. Describe the stages involved in ordinary glass bottle manufacturing.