AUTOMOBILE MANUFACTURING PROCESS (17403)

AMP
(17403)
Question Bank from Summer & Winter Exams

Mr. Dhaigude Pramod. B.

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AUTOMOBILE MANUFACTURING PROCESS (17403)

AMP (17403)
Question Bank from Summer & Winter Exams

CHAPTER – 1
2 Marks Questions
1) Name two parts manufactured by forging.
 Connecting Rod, Crankshaft, Spanner, Gear, Crane Hook, Camshaft
2) Define forging. Give two alloys used for forging.
2) Define forging. List any four forgeable materials.
 Point No. 1.1, Page No. 01, Point No. 1.3, Page No. 02
3) What is forgeability?
3) What is forgeability?
3) Define forgeability. List forgeable materials.
 Point No. 1.2, Page No. 01, Point No. 1.3, Page No. 02
4) Name any four hand tools used in forging.
4) Sketch any two hand tools which are used in forging process.
 Point No. 1.7, Page No. 06 – 12
5) State two methods of forging.
 Point No. 1.9, Page No. 15
6) Distinguish between open die & close die forging.
 Point No. 1.11, Page No.22
7) State any four advantages of forging process.
7) State advantages of forging process.
 Point No. 1.6, Page No. 05,06

4 Marks Questions
1) Write classification of forging process.
1) Give the classification of forging processes.
2) Point No. 1.9, Page No. 15
3) State the advantages of forging process.
2) Write down the advantages & limitations of forging processes.

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AUTOMOBILE MANUFACTURING PROCESS (17403)
2) Give advantages & disadvantages of forging process.
2) What are the limitations of forging?
2) Enlist the limitation of open die forging.
2) What are the advantages of press forging over drop forging?
 Point No. 1.6, Page No. 05, 06
3) Define forgeability. State the factors on which it depends.
3) What is forgeability? Enlist forgeable materials.
 Point No. 1.2, Page No. 01& Point No. 1.3, Page No. 02
4) Differentiate between open & closed die forging.
4) Distinguish between close type forging & open type forging.
4) Distinguish between open die forging & close die forging.
4) Compare open die forging & closed die forging min four points.
 Point No. 1.11, Page No.22
5) List forging hand tools. Explain with sketch how the swage block & anvil are
used.
 Point No. 1.7, Page No. 06 – 12
6) Explain with sketch the process of drop forging.
6) Explain with neat sketch process of drop forging.
6) With neat sketch describe process of drop forging.
6) Explain any one method of forging.
6) Explain drop hammer forging process with neat sketch & stat the automobile
components manufactured using this process.
 Point No. 1.9 II a, Page No. 19
7) Write forging sequences followed while manufacturing of connecting rod. State
material used for connecting rod.
7) With neat sketch write stages for manufacturing connecting rod by forging.
7) Explain the sequence of operation for forging of a connecting rod with sketches.
 Point No. 1.15 II, Page No. 28
8) Write down the forging sequence for crankshaft of engine.
8) Give forging sequence for making crankshaft.
8) With neat sketch write stages for manufacturing crankshaft by forging.
8) Describe forging operation for manufacturing of a crank shaft.

Mr. Dhaigude Pramod. B.

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AUTOMOBILE MANUFACTURING PROCESS (17403)
 Point No. 1.15 III, Page No. 29
9) Write the forging sequence for making spanner.
9) Explain the forging operation sequence to forge a spanner.
9) State the forging sequence for manufacturing gears.
9) Which manufacturing process is suitable for manufacture of spanners & small
gears? Justify your answer & explain the process.
9) Forging sequence for:
i. Gears
ii. Spanners.
 Point No. 1.15 I, Page No. 27, Point No. 1.15 IV, Page No. 30

CHAPTER – 2
2 Marks Questions
1) List the materials used in press work.
1) State the material used in press work.
 Point No. 2.2, Page No. 33
2) How presses are classified?
2) List the two drive mechanisms used in presses.
2) Classify the press according to design of frame.
 Point No. 2.3, Page No. 34
3) Name four parts of standard die set.
3) Enlist parts of a standard die set.
 Point No. 2.25, Page No. 52 – 56
4) What is shut height of a press?
 The distance from the slide faces to the bolster when the slide is at bottom dead
center.
 The shut height of an upright press is the distance from the top of the bed to the
bottom of the slide with stroke down and adjustment up.
 The shut height must always be defined either from the top of the bed or from
the top of the bolster.

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AUTOMOBILE MANUFACTURING PROCESS (17403)
 The shut height of a horizontal or inverted press, or of a press with adjustable
bed, can be defined in a similar manner.
 Generally the shut height is equal to the maximum die-height of the die that can
be accommodated, taking the bolster into consideration
5) Sketch any two cutting & forming operations performed on press.
 Point No. 2.22, Page No. 46 – 50
6) List any four press components used in automobiles.
 Point No. 2.1, Page No. 33

4 Marks Questions
1) Which materials are used to make press components?
 Point No. 2.2, Page No. 33
2) Give classification of presses & sketch any one.
2) Give detailed classification presses.
2) How are dies classified?
2) Write classification of press.
2) How are presses classified?
2) Classify the press on the basis of
i. Type of frame
ii. Type of work
iii. Number of slide
iv. Source of power.
2) State & explain any two type of driving mechanism used in press.
2) Explain any two drive mechanisms used in press with sketches.
2) Describe drive mechanism used on presses.
2) How dies are classified. State its automobile component manufacturing
application.
 Point No. 2.3, Page No. 34
3) Draw a neat sketch of fly press & label its major parts.
3) How the fly press works? Explain with sketch.
3) Draw a sketch of fly press & show major parts on it. Write their functions.
 Point No. 2.5, Page No. 35, 36

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AUTOMOBILE MANUFACTURING PROCESS (17403)
4) Draw a neat labeled sketch of punch & die set used for blanking operations.
4) Sketch standard die set & label it.
4) List all the die accessories & sketch any one.
4) Draw a neat labeled sketch of punch & die set used for blanking operation.
4) What are different die accessories describe each in brief.
4) Explain the parts of a standard die set with sketch. Write functions of any four
parts.
4) Draw a neat labeled sketch of punch & die set used for punching operation.
4) Draw a simple cutting die and label all the parts.
 Point No. 2.25, Page No. 52 – 56
5) Sketch & explain a progressive die to make a washer.
5) Give construction of progressive die with neat sketch used for punching.
5) Explain the progressive die with neat sketch & construction.
 Point No. 2.29, Page No. 58
 A progressive or follow on die has a series of operations.
 At each station, an operation is performed on a work piece during a stroke
of the press.
 Between strokes the piece in the metal strip is transferred to the next
station.
 A finished work piece is made at each stroke of the press.
 While the piercing punch cuts a hole in the stroke, the blanking punch
blanks out a portion of the metal in which a hole had been pierced at a
previous station.
 Thus after the first stroke, when only a hole will be punched, each stroke
of the press produces a finished washer.
6) Differentiate compound die & combination die.
6) Explain washer making process using combination die.
6) Differentiate between compound & combination die.
6) Differentiate between compound die & combination die.
6) Compare compound dies & combination dies.
 Point No. 2.27, Page No. 56, & Point No. 2.28, Page No. 57
7) List all the press operations & sketch any one.

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AUTOMOBILE MANUFACTURING PROCESS (17403)
7) Explain shearing operation with sketch on a press.
7) Differentiate coining & embossing.
7) Explain drawing operation on press.
7) Explain nibbling & perforating.
7) Differentiate punching & blanking with neat sketches.
7) Differentiate between banking & piercing operations.
7) What is perforating? How it differs from punching?
7) Explain blanking & piercing operation on press with sketch. What is major
difference between these two?
7) Explain deep drawing operation with sketch.
7) Name common shearing operations performed on a press & explain any two of
them.
7) With neat sketch explain drawing operation performed on press.
7) Differentiate between punching & blanking with sketches.
7) Define the following press operation:
i. Punching
ii. Piercing
iii. Blanking
iv. Trimming.
7) Draw & state function of :
i. Deep drawing
ii. Embossing.
7) Explain the following operation with sketches.
i. Piercing
ii. Perforating
 Point No. 2.22, Page No. 46 – 50
8) Explain working of stop & pilots used in press.
8) Compare between fixed and spring loaded stripper.
 Point No. , Page No. 53 – 56
 After a blank has been cut by the punch on its downward stroke, the scrap strip
has the tendency to expand.
 On the return stroke of the punch the scrap strip has the tin denied to adhere to

Mr. Dhaigude Pramod. B.

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AUTOMOBILE MANUFACTURING PROCESS (17403)
the punch and be lifted by it.
 This action interface with the feeding of the stroke through the die and some
device must be used to strip the scrap material from the punch as it clears up the
die block.
 Such a device is called “stripper” or stripper plate.
 Stripper plates are of two types:
 1: fixed or stationary
 2: spring loaded or movable

 (a): Fixed Or Stationary Strippers:

 This stripper is attached at a fixed height over the die block.
 The height should be sufficient to permit the sheet metal to be fed freely between
the upper die surface and the under surface of the stripper plate.
 The stripper plate thickness is determining by the formula:
 Ts =1/8(w/3+16t)
 Where w and t are width and thickness of the stock strip.
 The fixed stripper is also known as ‘channel stripper”
 (b): Spring Loaded Stripper:
 This type is used on large blanking operations and also on very thin and highly
ductile materials.
 As the punch travels downward for blanking operation the stripping force is
determined with the help of following relation.
 Fs=spt kn

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AUTOMOBILE MANUFACTURING PROCESS (17403)
 Where p and t are in mm and s is the stripping constant.
9) What are pilots? State the types of pilots.
9) Explain working of stop & pilots used in press.
 Pilots:-
 Pilots are used in progressive dies.
 In the design of progressive dies, the first step is to establish the sequence of
operations.
 In this sequence, the piercing operations are placed first.
 After the holes have been pierced, these holes are used for piloting the blanking
punches so that the blank formed is truly concentric to the already punched hole.
 This piloting is achieved by means of pilots secured under the blanking punch.
 To be effective the pilot must be strong enough to align the stock without
bending.
 Pilots are made of good grade of tool steel heat treated to maximum toughness
and to a hardness of 56 to 60 Rockwell C.

Types of pilots: there are two types of pilots:

 (a ): Direct Pilot:
 Pilots which are mounted on the face of a punch are called direct pilots.
 The pilot holder is generally a block of steel which can be fastened to the punch
holder.
 (b) Indirect Pilot:
 Such pilots are well guided through the hardened bushes in the stripper plate.
10)What are the major parts of a mechanical press? Explain functions of any four

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AUTOMOBILE MANUFACTURING PROCESS (17403)
parts.
10)Describe working of mechanical power press with neat sketch.
 Point No. 2.5 to 2.21, Page No. 35 to 46
11)Explain with sketch how clearance is provided on punch & die.
11)Explain with sketch why punch & die clearance are provided.
11)Explain with sketches why punch & die clearance are provided.
11)Explain with sketch why punch & die clearances are provided?
 Point No. 2.30, Page No. 59, 60.
 Clearance
 The difference in dimensions between the mating members of a die set is called
clearance. This clearance is applied in following manner:
 When the hole has to be held to size i.e. the hole in the sheet metal is to be
accurate (punching operation), and slug is to be discarded.
 The punch is made to the size of the hole and the die opening size is obtained by
adding clearance to the punch size.
 2: In blanking operation, where the slug or blank is the desired part and has to be
held to size, the die opening size equals the blank size and the punch size is
obtained by subtract.

Mr. Dhaigude Pramod. B.

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AUTOMOBILE MANUFACTURING PROCESS (17403)

CHAPTER – 5 & 6
2 Marks Questions
1) State the meaning following CNC codes.

G41 G94 G00 G17

1) State any four modal G codes.

 Point No. 5.22, Page No. 80 – 82
2) State the meaning of numerical control.
3) What are the elements of NC system?
 Point No. 5.1 & 5.3, Page No. 61 & 63
4) List any four advantages of CNC machines.
 Point No. 5.8, Page No. 66
5) Classify CNC machines based on control system features.
5) Give the classification of CNC machines.
 Point No. 5.14, Page No. 69

4 Marks Questions
1) Compare between open loop & closed loop control system.
 Point No. 5.16, Page No. 72
2) Draw a closed loop feedback system & explain it.
2) Draw & label closed loop system of CNC machine.
 Point No. 5.15 b, Page No. 71, 72
3) Give advantage of CNC over NC machines.
3) Write the advantages & disadvantages of CNC machines.
3) What are the advantages & disadvantages of CNC machines?
 Point No. 5.8, Page No. 66 & Point No. 5.9, Page No. 66
4) With the help of sketch explain the use of absolute & incremental system.
4) Explain absolute & incremental co – ordinate system.
 Point No. 5.18 1 & 5.19 2, Page No. 75, 76
5) Explain working principle of CNC machine with block diagram.

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AUTOMOBILE MANUFACTURING PROCESS (17403)
6) Describe working principle of CNC machine using block diagram.
 Point No. 5.5 & 5.6, Page No. 63, 64
7) With the help of figure explain axis identification for VMC.
7) How axes are identified in CNC machines? Sketch the arrangement of axis.
7) with the help of figure explain axis identification for VMC
7) Explain axis identification on CNC milling machine.
 Point No. 5.21, Page No. 79, 80
8) Distinguish between NC & CNC systems.
8) Differentiate NC machines & CNC machines.
 Point No. 5.13, Page No. 68, 69
9) Differentiate DNC & CNC machines.

DNC CNC
Computers distribute instructional data to Computers control only one
and collect from a large number of machine or a small number of
machines. machines.
DNC computers occupy a location that is CNC computers are located very
typically remote from the machines under near their machine tools.
their control.
DNC software is developed not only to CNC software is developed to
control individual pieces of production augment the capabilities of a
technology but also to serve as part of particular machine tool.
management information system in the
manufacturing sector of the firm.
Except for the fact that a digital computer
CNC machines are similar and the
is used part programs are entered in a
similar manner
Punched tapes are still the common device Punched tapes are still the
for entering the part program into the common device for entering the
system part program into the system
10)Differentiate between absolute & incremental co – ordinate system.
 Point No. 5.18, Page No. 75, 76
11)Give classification of NC / CNC system on the basis of control on tool motion.
11)Give classification of CNC machines.
11)Write working principle & classification of CNC machines.
11)Classify the CNC machines based on feedback control & control system features.
11)Give the basis of CNC machines classification. State their names.
 Point No. 5.14, Page No. 69

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12)Write advantages & limitation of CNC machines.
12)Write advantages & disadvantages of CNC machines.
12)Write the advantages & disadvantages of CNC machines.
12)Write advantages & disadvantages of CNC machines.
 Point No. 5.8 & 5.9, Page No. 66
13)State different reference positions used on CNC machines.
 Point No. 5.20, Page No. 78
13)Y State Meaning of each constituent of block format.
 Point No. 5.24, Page No. 84
13)Give the meaning of following codes:
G00 G02 G04 G90
M06 M08 M05 M30

13)Give ISO codes used in programming.

 Point No. 5.22, Page No. 80 – 83
14) Explain procedure for developing part program.
 Point No. 5.25, Page No. 85, Point No. 5.26, Page No. 86, 87

8 Marks Questions
1) Compare between the following codes in brief:
i. G02 & G03
ii. G94 & G95
iii. G41 & G42
iv. M02 & M03
1) Give the meaning of following codes:
i. G00, G01, G04, G70 ii. M02, M03, M08, M30
1) Give the meaning of the following codes.
i. G00, G01, G70, G90
ii. M03, M06, M08, M30
1) Write with their meaning of any four functional & any four non – functional
codes used in programming.
 Point No. 5.22, Page No. 80 – 83
2) Compare CNC & NC machines.
 Point No. 5.13, Page No. 68, 69

Mr. Dhaigude Pramod. B.

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AUTOMOBILE MANUFACTURING PROCESS (17403)

 CHAPTER – 3
2 Marks Questions
1) Name & sketch the types of flames used in gas welding.
 Page No. 111
2) Why is neutral flame extensively used in oxy – acetylene welding?
2) Why is neutral flame extensively used in oxy – acetylene welding?
 Page No. 111
3) Give any four applications of seam welding.
 Page No. 124
4) Spot welding machine electrode are made up of copper alloy instead of pure
copper. Why?
 Page No. 122
5) Describe working principle of gas welding.
6) State the working principle of gas welding.
6) Explain working principle of gas welding.
6) Describe the working principle of gas welding.
 Page No. 108 – 110
7) Working principle of TIG welding.
7) State the application of TIG welding in automobile industry.
 Page No. 118, 119
8) State the principle of arc welding.
 Page No. 114, 115

4 Marks Questions
1) Give the classification of welding process.
1) Give classification of welding processes.
 Page No. 107
2) Explain TIG welding process.
2) Compare TIG & MIG welding.

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AUTOMOBILE MANUFACTURING PROCESS (17403)
2) Compare TIG & MIG welding process. State its applications.
2) Explain T.I.G. welding with advantages.
 Page No. 117 – 119
3) What are the types of resistance welding? Explain spot welding process.
3) Explain resistance welding process with the help of neat sketch.
3) What are the benefits of resistance welding over arc welding?
3) Distinguish between resistance & arc welding.
3) Differentiate between resistance welding & arc welding.
 Page No. 120 - 124
4) Write the steps in brazing. Which are the components of brazing?
 Page No. 129, 130
5) Differentiate between brazing & soldering.
5) Distinguish between soldering & brazing.
5) Differentiate between soldering & brazing.
5) Distinguish between brazing & soldering.
5) Give difference between soldering & brazing.
5) Differentiate brazing & soldering.
5) Differentiate between brazing & soldering.
 Page No. 131
6) Sketch & explain principle of spot welding.
6) What are the advantages of spot welding?
6) What are the advantages of spot welding?
 Page No. 121
7) Explain OAW flame setting.
 Page No. 109
8) Define welding. What are the types of welding joints?
 Page No. 106
9) Explain leftward & rightward welding technique. What are the advantages of R.H.
welding over L.H. welding?
 Leftward or Forward Welding
 The leftward method of welding is also known as forward welding.
 It is the oldest and most widely established method for the butt-welding of steel

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plates.
 Recent developments have shown that above certain thickness, the leftward
method cannot be used successfully, but within its sphere of application, which is
limited of thickness, it gives excellent results.
 And it is the most satisfactory method, both from the point of view of the
economy of the joint and the resultant mechanical properties of the weld.
 Welding is commenced at the right hand edge of the plate and proceeds across
the plane in a leftward direction, the blowpipe following the welding rod.

 It is necessary to bevel the plate’s upto 1/8” thickness

 But there should be an included angle of bevel of at least 80º for thickness
between 1/8”and 3/16”, above 3/16” thickness under normal condition
 It is not economical to use the leftward method and it should be replaced by
rightward method.
 Rightward or Backward Welding
 During the past few years much publicity has been attached to the rightward
method of welding and the results obtained by this method.
 Investigations show that the all these claims have been adequately sustained.
 The rightward method of welding consists of commencing at the left-hand side of
the plate and proceeding towards the right, the filler rod following the blowpipe
(Refer Fig).
 It will be observed that the blowpipe point in the direction of the completed weld
and that it moves regularly along the seam.
 There is no lateral movement of the blowpipe, rather the end of the filler rod
describes a series of loops and doesn’t progress steadily as in case of the leftward

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welding.
 It is not necessary to bevel the edges of the plate between 3/16” to 5/16” and
even when a bevel is necessary the included angle should be only 60º and 80º as
in the previous case.
 Further differences, all of which must be learnt and remembered if the method is
to be applied successfully, are that the welding rod is held at an angle of 40º-50º
to the job and not 30º-40º,
 This is the case in leftward welding. On other hand, the blowpipe is held much
flatter
 i.e. the angle of the blowpipe to the plate is only 40º-50º as compared with the
60º-70º required in the case of leftward method.
 These differences in the angle of the bevel, movement of the rod, angle of the
filler rod and angle of blowpipe are of real importance and significance.

 With regard the mechanical properties of the weld, the enhance ductility,
elongation etc., are due to the annealing effects.
 The flame playing on the finished weld prevents the weld zone from cooling
down suddenly and so prevents brittle deposit.
 There is less risk of excessive oxidation. A further advantage is that the heat is
more localized and consequently, the effects of distortion are greatly reduced.
10)Explain M.I.G. welding process.
10)With neat sketch explain MIG welding process.
 Page No. 117, 118
11)Explain types of flames with neat sketches.
11)Name various types of flames used in gas welding. State their applications. Draw

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sketches.
11)Explain the various types of flames. Explain any one of them.
 Page No. 111, 112
12)Explain plasma arc welding. State its specific application.
13)What is plasma arc welding & write the specific applications pertaining to auto
industry?
 Page No. 119, 120
14)Y Difference between arc welding & resistance welding.
 Y Page No. 125
15)Explain projection welding with sketch & state its application in automobile
industry.
15)Explain with neat sketch the projection welding process.

 Projection welding description:

 Projection welding is a development of resistance spot welding.

 In spot welding, the size and position of the welds are determined by the size of
the electrode tip and the contact point on the workpiece, whereas in projection
welding the size and position of the weld or welds are determined by the design
of the component to be welded.

 The force and current are concentrated in a small contact area which occurs
naturally, as in cross wire welding or is deliberately introduced by machining or
forming.

 An embossed dimple is used for sheet joining and a 'V' projection or angle can be
machined in a solid component to achieve an initial line contact with the
component to which it is to be welded.

 Process:

 Projection welds are produced at localized points in workpiece held under

pressure between suitable electrodes. Sheet metal is first put through a punch
press that makes small projections or buttons in the metal.

 These projections are made with a diameter on the face equal to the thickness if
the stock and extend from the stock about 60% of its thickness.

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AUTOMOBILE MANUFACTURING PROCESS (17403)

 Such projection spots or ridges are made at all points where a weld is desired.

 This process is also used for crosswire welding and for parts where the ridges
are produced by machining.

 With this form of welding a number of welds can be made simultaneously.

 The only limit is the ability of the press to furnish and distribute equally the
correct current and pressure.

 Results are generally uniform and weld appearance often do better than spot
welding.

 Electrode life is long, because only flat surfaces are used and little electrode
maintenance is required.

 Consequently, multiple welds can be made more easily at the same time, and
thicker sections can be joined more readily than in RSW.

 Other advantages include reduced shunting effects, closer weld-to-weld spacing

and welding of workpiece with smaller flanges.

 Advantages of Projection Welding:

 More than one spot weld can be made in a single operation.

 Welding current and pressure required is less.

 Suitable for automation.

 Filler metals are not used. Hence, clean weld joints are obtained.

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 Disadvantages of Projection Welding:

 Projections cannot be made in thin work pieces.

 Thin work pieces cannot withstand the electrode pressure.

 Equipment is costlier.

 Applications of Projection Welding:

 A very common use of projection welding is the use of special nuts that have
projections on the portion of the part to be welded to the assembly.

 Also, used for welding parts of refrigerator, condensers, refrigerator racks, grills
etc

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CHAPTER – 4
2 Marks Questions
1) List any four surface finishing processes.
1) List two finishing processes applied to automobile products.
1) State applications of surface finishing process.
1) List two finishing processes applied to automobile products.
 Point No. 4.9, Page No. 144 – 157
2) List two surface cleaning processes applied to automobile components.
 Point No. 4.7, 4.7.1, Page No. 133 – 134
3) Write the procedure of metal spraying with sketch & give its applications.
 Point No. 4.8 c), Page No. 139 – 141
4) State any two factors on which selection of finishing process depends.
 Point No. 4.9.1, Page No. 144
5) State the principle of electrolytic cleaning.
 Point No. 4.7.1C, Page No. 135

4 Marks Questions
1) State the need of surface finishing operations.
 Point No. 4.9.1, Page No. 144
2) Explain electroplating as a surface treatment process.
 Point No. 4.8 a), Page No. 149 – 152
3) Explain the process of honing with sketch.
3) Explain honing process for cylinder liner of an automobile.
3) List applications of honing process in automobile industry.
 Point No. c) , Page No. 87,88,89
4) Differentiate honing & lapping process.
4) Explain lapping & honing processes. State their use.
4) Compare honing & lapping process.
4) Differentiate between lapping & honing process on the basis of finishing quality

Mr. Dhaigude Pramod. B.

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AUTOMOBILE MANUFACTURING PROCESS (17403)
& application.
 Point No. , Page No. 153
5) Explain hand lapping & machine lapping process with their applications.
 Point No. , Page No. 147 – 149
6) Explain buffing process with neat sketch.
 Point No. , Page No. 155, 156
7) Explain lapping & buffing surface finish processes.
 Point No. , Page No. 145 – 149, & 155, 156
8) List the various processes used for surface cleaning. Explain any one.
8) What are different surface cleaning processes? Explain any two in detail.
 Point No. 4.7, 4.7.1, 4.7.2, & Page No. 133 – 137
9) Explain shot blasting surface cleaning process.
 Shot Blasting
 Shot Blasting is the industry-recognized method of preparing concrete floors.
 It’s a one-step surface preparation technique that removes, cleans and profiles
the surface in a single application. It can effectively remove laitance, paint, old
coatings, dirt and other contaminants that are in or on concrete.
 This process will prepare new concrete or steel for coating applications and will
enhance and improve the bond for any type of coating system.
 Shot Blasting is a dust-free method of surface abrasion in which thousands of
steel shot particles are propelled at the surface removing the top layer and
contaminants and bounce back into the system to be recycled.
 The steel shot profiles the surface, while contaminants are removed by the dust
collection recovery system.

10)Explain electroplating surface coating process.

10)Explain electroplating process with neat sketch.
10)Explain the process of electroplating using suitable diagram.
 Point No. 4.8 a), Page No. 138 – 139

Mr. Dhaigude Pramod. B.

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AUTOMOBILE MANUFACTURING PROCESS (17403)
11)Write advantages of electroplating process.
11)W rite advantages of electroplating process.
Advantages/Strengths Disadvantages/Limitations
Deposit is extremely hard and wear Slow rate of deposition; multiple coats
resistant often needed

Thick deposits can be machined for

repair/tolerance applications
Simple, well-understood technology
Wide range of applications
Surface offers good lubricity
characteristics
Machining needed to get uniform thickness
Susceptible to hydrogen in brittleness
Exhibits brittleness, leading to micro-
cracking and reduced corrosion resistance
Decontamination of plating solutions is
difficult

In combination with nickel under

plating, it can offer good corrosion
resistance
12)What are the factors to be considered for selection of cleaning process?
 Point No. 4.6, Page No. 133
13)List chemical cleaning processes. Explain any one of them.
 Point No. 4.7.1, Page No. 133 – 135
14)Explain electrolytic process. State its use in automobile industry.
 Point No. 4.7.1 C, Page No. 135
15)Explain buffing & burnishing operations used in automobile industry.
15)State application of buffing & burnishing process in automobile component
manufacturing.
 Point No. , Page No. 154 – 157
16)Distinguish between metal spraying & painting.
16)Briefly explain metal spraying & painting process.
16)Explain metal spraying & painting process.
16)Explain meal spraying process.
 Point No. 4.8 c), Page No. 139, 140 & Point No. 4.8 d), Page No. 141
17)State factors to be taken into account while selecting a surface treatment &
finishing process for a particular component.
17)Explain the finishing processes used for following components:
i. Cylinder liner ii. Crankshaft.

Mr. Dhaigude Pramod. B.

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AUTOMOBILE MANUFACTURING PROCESS (17403)
17)Explain the finishing processes for following components:
i. Crank shaft
ii. Cylinder liner
 Point No. , Page No. 149

Grinding Crankshaft
Honing Cylinder Liner
Lapping Valve
Buffing Shock Absorber Rods
18)Explain galvanizing process with neat sketch. State its application in automobile
industry.
 Point No. 4.8 b), Page No. 139
19)Explain blasting & tumbling processes. State their use.
 Point No.4.7.2 a) & point no. 4.7.2 b), Page No. 136, 137

Mr. Dhaigude Pramod. B.

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