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TABLE OF CONTENT
S.NO TOPIC PAGE NO.

1 Syllabus 4
2 Aim and Objective of the Subject 5
3 Detailed Lesson Plan 7
UNIT I BASICS OF METROLOGY
4 Part - A (2 Marks Q &A) 9
5 Part - B (13 Marks Q &A) 11
6 Part –C(15MarksQ&A) 20
UNIT II LINEAR AND ANGULAR MEASUREMENTS
7 Part - A (2 Marks Q &A) 26
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8 Part - B (13 Marks Q &A) 30
9
w Part –C(15MarksQ&A)
.Ea UNIT III ADVANCES IN METROLOGY

37
10
11 sy E
Part - A (2 Marks Q &A)
Part - B (13 Marks Q &A)
41
44
12 Part –C(15MarksQ&A)
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UNIT IV FORM MEASUREMENT
57
13 Part - A (2 Marks Q &A) nee 61

14 Part - B (13 Marks Q &A)
rin 64
15 Part –C(15MarksQ&A)
UNIT V MEASUREMENT OF POWER, FLOW AND TEMPERATURE g.n 77
16
17
Part - A (2 Marks Q &A)
Part - B (13 Marks Q &A)
79
81
et
18 Part –C(15MarksQ&A) 96
ANNA UNIVERSITY PREVIOUS YEAR QUESTION PAPERS
19 Nov/Dec 2010 99
20 May/June 2012 101
21 Nov/Dec 2012 104
22 May/June 2013 107
23 Nov/Dec 2013 110
24 May/June 2014 112

25 Nov/Dec 2014 115

26 April/May 2015 118
27 Nov/Dec 2015 120
28 May/June 2016 123
29 Nov/Dec 2016 126
30 April/May 2017 129
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ME6302 MANUFACTURING TECHNOLOGY –I LTPC

3 0 03
UNIT I METAL CASTING PROCESSES 9
Sand Casting : Sand Mould – Type of patterns - Pattern Materials – Pattern
allowances –Moulding sand Properties and testing – Cores –Types and
applications – Moulding machines– Types and applications; Melting furnaces :
Blast and Cupola Furnaces; Principle of special casting processes : Shell -
investment – Ceramic mould – Pressure die casting - Centrifugal Casting - CO2
process – Stir casting; Defects in Sand casting
UNIT II JOINING PROCESSES 9
Operating principle, basic equipment, merits and applications of : Fusion
welding processes : Gas welding - Types – Flame characteristics; Manual metal
arc welding – Gas Tungsten arc welding - Gas metal arc welding – Submerged
arc welding – Electro slag welding; Operating principle and applications of :
Resistance welding - Plasma arc welding – Thermit welding – Electron beam
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welding – Friction welding and Friction Stir Welding; Brazing and soldering;
Weld defects: types, causes and cure.
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UNIT III METAL FORMING PROCESSES
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Hot working and cold working of metals – Forging processes – Open,
9
impression and closed die forging – forging operations. Rolling of metals–
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Types of Rolling – Flat strip rolling – shape rolling operations – Defects in
rolled parts. Principle of rod and wire drawing – Tube drawing – Principles of
UNIT IV SHEET METAL PROCESSES ngi

Extrusion – Types – Hot and cold extrusion.
9
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Sheet metal characteristics – shearing, bending and drawing operations –
Stretch forming operations – Formability of sheet metal – Test methods –
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special forming processes-Working principle and applications – Hydro forming
g.n
– Rubber pad forming – Metal spinning– Introduction of Explosive forming,
magnetic pulse forming, peen forming, Super plastic forming – Micro forming
UNIT V MANUFACTURE OF PLASTIC COMPONENTS
Types and characteristics of plastics – Moulding of thermoplastics – working
principles and typical applications – injection moulding – Plunger and screw
9
et
machines – Compression moulding, Transfer Moulding – Typical industrial
applications – introduction to blow moulding –Rotational moulding – Film
blowing – Extrusion – Thermoforming – Bonding of Thermoplastics
TEXT BOOKS:
1. Hajra Chouldhary S.K and Hajra Choudhury. AK., "Elements of workshop
Technology", volume I and II,
REFERENCES:
1. Gowri P. Hariharan, A.Suresh Babu, "Manufacturing Technology I",
Pearson Education, 2008
2. Sharma, P.C., "A Text book of production Technology", S.Chand and Co.
Ltd., 2004.
4

Aim
 To introduce the concepts of basic manufacturing processes and

fabrication techniques, such as metal casting, metal joining, metal
forming and manufacture of plastic components
Course objective
 To understand the basic fundamentals of manufacturing process
 To get wide view knowledge about the metal casting, metal joining
metal forming & plastic component of manufacturing technique & ideas
 To learn practical knowledge about foundry & welding area
 To apply the different manufacturing process like sheet metal and bulk
ww deformation process and use this in industry for producing component.
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 To learn latest automation techniques, testing and to produce Defect less
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manufacturing product To Understand the ethical issues in
manufacturing process
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 To make a new manufacturing product with the help of latest
mechanical 3D software
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 Once understood the Manufacturing methods (casting, welding,
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forming, and plastic molding process) and they are run in the small scale
industry.
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Web resources:
kalpakjin:http://www.nd.edu/manufact/index3.htm g.n
www.general manufacturing.engineer.com et
The American welding society:
http://aws.org/w/s/technical/facts/index.html
Welding guideline:
www.gov.mb.ca/labour/safety/pdf/welding_guide.pdf

Industry / Practical connectivity of the subject:
1. Balaji foundary services- copper based alloys LTB Phosper bronze

centrifugally casted Gearblanks,
Address: No114, athipalayam road, Ganapathy Kottaram,Coimbatore-641006
2. Aiswarya polymers Hylam, Fiber copper clad red fibre syndanyo, Glass
Epoxy nyon rods Fibre Glass products
Address:No-6 senalipalayam Nggo colony, Thydiyalur Coimbatore-641022
3. Meal casting process (small scale industries brass lamp casted kaariyeruppu-
tirunelveli ,and home vessels like aluminium and brass lamp casted from small
scale industries vaagaikulam –Ambasamuthiram Tirunelveli
DEPARTMENT OF MECHANICAL ENGINEERING
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Detailed Lesson Plan
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Name of the Subject& Code: ME6302/ Manufacturing Technology -I
TEXT BOOKS: .Ea

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1. Hajra Chouldhary S.K and Hajra Choudhury. AK., "Elements of workshop
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Technology", volume I and II, Media promoters and Publishers Private
Limited, Mumbai, 1997
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2. Kalpakjian. S, “Manufacturing Engineering and Technology”, Pearson
Education India Edition, 2006
REFERENCES: rin
1. Gowri P. Hariharan, A.Suresh Babu, "Manufacturing Technology I", g.n
Pearson Education, 2008
2. Roy. A. Lindberg, "Processes and Materials of Manufacture", PHI / Pearson

et
education, 2006
3. Paul Degarma E, Black J.T and Ronald A. Kosher, "Materials and Processes,
in Manufacturing" Eight Edition, Prentice – Hall of India, 1997.
4. Sharma, P.C., "A Text book of production Technology", S.Chand and Co.
Ltd., 2004.
5. Rao, P.N. "Manufacturing Technology Foundry, Forming and Welding",

2ndEdition, TMH-2003

NO OF CUMULATIVE BOOKS
S.NO UNIT TOPICS COVERED
HOURS HOURS REFERRED
UNIT-I METAL CASTING PROCESSES
1 Sand Casting : Sand Mould 1 1 TI, R1
2 Type of patterns 2 3 TI, R1
3 Pattern Materials, Pattern allowances 2 5 T1, R1
4 Moulding sand Properties and testing 2 7 T1, R1

Cores –Types and applications –
5 2 09 T1, R1
Moulding machines
1 Types and applications; Melting furnaces
6 1 10 T1, R1
: Blast and Cupola Furnaces
Principle of special casting processes :
7 1 11 T1, R1
Shell - investment – Ceramic mould
Pressure die casting - Centrifugal
8
9
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CO2 process – Stir casting;
1
1
12
13
T1, R1
T1, R1
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Defects in Sand casting
UNIT – II METAL JOINING PROCESSES
1 14 T1, R1
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Operating principle, basic equipment,
merits and applications of : Fusion 1 15 TI, R1
12
welding processes
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Flame characteristics – Filler and Flux
1 16 TI, R1
13
materials
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Arc welding equipments – Electrodes -
1 17 T1, R1
Coating andspecifications
Principles of Resistance welding – rin
14 Spot/butt, seam welding,Percusion
welding
1
g.n
18 T1, R1
15
16
2 seam welding – Percusion welding Gas
metal arc welding –Flux cored Welding,
Submerged arc welding , Electro slag
1
1
19
20
et T1, R1
T1, R1
welding , TIG welding
special welding processes - Plasma arc
17 welding – Thermitwelding – Electron 2 22 T1, R1
beam welding
Friction welding , Diffusion welding,
18 1 23 T1, R1
Weld defects
Brazing and soldering process, Adhesive
19 1 24 T1, R1
Bonding
UNIT- III METAL FORMING PROCESSES
20 Hot working and cold working of metals 1 25 T1, R1
3
21 Forging processes – Open, impression 2 27 T1, R1

and closed die forging- Characteristics

22 Types of Forging Machines 1 28 T1, R1
23 Forging Operations 1 29 T1, R1
24 Rolling Mills - types 1 30 T1, R1
Shape rolling operations, Defects in T1, R1
25 1 31
rolled parts
26 Rod, tube and wire drawing 1 32 T1, R1
27 Extrusion principle, types 1 33 T1, R1
28 Hot & Cold Extrusion 1 34 T1, R1
UNIT- IV SHEET METAL PROCESSES
29 Sheet metal characteristics 1 35 T1, R1
30 Shearing Operations - types 1 36 T1, R1
31 Bending and Drawing operations 1 37 T1, R1
32 Stretch forming operations 1 38 T1, R1
33 ww Formability of sheet metal - Test

methods
1 39
T1, R1
34
4
wSpecial forming processes - Hydro
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forming –Rubber pad formng
Metal spinning, Explosive forming,
2 41
T1, R1
T1, R1
35
36
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Magnetic pulse forming
Peen forming, Super plastic forming.
1
1
42
43 T1, R1
37 Micro forming
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38 nee
UNIT- V MANUFACTURING OF PLASTIC COMPONENTS
Types of plastics - Characteristics of the
1 45
T1, R1
forming processes
Types of plastics - Characteristics of the rin T1, R1
39
shaping processes
Working principles and Industrial
1 46
g.n T1, R1
40
41 5
application
Compression moulding
1
1
47
48
et T1, R1
42 Transfer moulding 1 49 T1, R1
43 Blow moulding 1 50 T1, R1
44 Rotational moulding – Film blowing 1 51 T1, R1
Extrusion, Thermoforming, Bonding of T1, R1
45 1 52
Thermoplastics.
46 Bonding of Thermoplastics. 1 53 T1, R1

UNIT I- METAL CASTING PROCESS

PART-A
1. Define pattern. (May/June-2014)
The model of the required casting made in wood, metal or plastics.
2. Define Casting (May/June-2014)
Casting is process of producing metal parts by pouring molten metal
into the mould cavity of the required shape and allowing the metal to solidify.
3. What is the function of core in moulding sand? (April/May -2015
&NOV/DEC- 2016)
To provide a hollow surface or recess on the casting, the core is made of sand.
4. State any four types of patterns. (Nov/Dec-2010) & (April/May -2015)
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, (May/June-2012) & (May/June-2016)
i. Solid pattern or single-piece pattern.
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iii.
Split pattern.
Loose piece pattern.
iv.
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5. Name four different casting defects. (Nov/Dec-2013)
i.
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Design of casting and pattern
ii.
iii. nee
Moulding and design of mould and core
Metal composition
iv. Melting and pouring rin
v. Gating and risering
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6. List any four products manufactured by using centrifugal casting
process. (Nov/Dec-2014) et
i. Water pipes iii. Brake drums
ii. Bush bearings iv. Gun Barrels
7. What is the function of runner and riser. (Nov/Dec-2015)
Runner: i) It is used to make a sprue a hole in the cope.
ii) It receives the molten metal from the pouring basin and passes
to the cavity.
Riser: i) It supplies excess molten metal to the solidifying casting.
ii) It allows the escape of air.

8. What is core print? Mention its purpose. (Nov/Dec-2012) &

(Nov/Dec-2012)
A core print is an extra projection on the pattern. It supports the core.
9. Write the composition of good moulding sand
Green Sand: It contains 5 to 8% of water and 15 to 20% clay.
Loam Sand: Loam sand is a mixture of fine sands, fine refractories, clay,
graphite powder and water. It contains more than 50% clay.
10. List the factors to be considered in the choice of metal melting
furnaces. (Nov/Dec-2012)
ww 1. Cupola Furnace: For cast iron.

2. Open hearth furnace - For steel.
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3. Crucible furnace - For non-ferrous metal.
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4. Electrical furnace - For steel, alloy steel, brasses.
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11. What is meant by grain fineness number? (Nov/Dec-2014)
Grain Fineness Number (GFN) is a measure of the average size of the
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Grains in sand AFS Grain Fineness Number (AFS-GFN), introduced by
American Foundry Society,
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12. Write a note on chilled casting.
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(Nov/Dec-2010)
A chill is an object used to promote solidification in a specific portion of a
metal casting mold. Normally the metal in the mold cools at a certain rate et
relative to thickness of the casting.
13. Compare the advantage of metal moulds over sand moulds.
(May/June-2013)
 The main difference between sand casting and die casting is , in die
casting the tool used to make the shape of product is a permanent tool
and the can be used again and again for making the same component.
But in sand casting, the tool i.e sand pattern is destroyed after making on
component.
10

 Die casting is economically benefiting for high productive

environment than sand casting.
 Dimensional repeatability of the component can be assured in die
casting compared to sand casting
14. What are Chaplets? (May/June-2016)
Sometimes it is not possible to provide sufficient support for a core in
the moulding being poured, if the cores are bigger in size. In such case
the core is supported with rigid metal pieces called chaplets
15. What are causes for the formation of blow holes in the sand casting?
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 Not adequately vented mould

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 Excess moisture in the molding sand
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 Low permeability and excessive fine grain sand
 Rusted damp chills, chaplets and inserts

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 Presence of gas producing ingredients in the mold or core
sands
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 Extra hard ramming sands
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PART-B
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1. Explain the properties of moulding sands. (Dec-2009, 2010, 2012
May2010, 2013& Dec-2016)
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1. Strength:
 The sand should have adequate strength in its green, dry and hot states
Green strength is the strength of sand in the wet state and is required for
making possible to Prepare and handle the mould.
 If the metal is poured into a green mould the sand adjacent to the metal
dries and in the dry state it should have strength to resist erosion and the
pressure of metal.
11

 The strength of the sand that has been dried or basked is called dry
strength at the time of Pouring the molten metal the mould must be able
to withstand flow and pressure of the Metal at high temperature
otherwise the mould may enlarge, crack, get washed or break
Strength of the moulding sand depends on:
1. Grain size and shape
2. Moisture content
3. Density of sand after ramming
The strength of the mould increases with a decrease of grain size and an
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increase of clay content and density after ramming. The strength also goes
down if moisture content is higher than an optimum value.
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2. Permeability:
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The moulding sand must be sufficiently porous to allow the dissolved
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gases, which are evolved when the metal freezes or moisture present or
generated within the moulds to be removed freely when the moulds are poured.
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This property of sand is called porosity or permeability.
3. Grain size and shape:
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The size and shape of the grains in the sand determine the application in
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various types of foundry. These are three different sizes of sand grains.
1. Fine
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2. Medium
3. Coarse et
 Fine sand is used for small and intricate castings. Medium sand is used
for benchmark and light floor works. If the size of casting is larger
coarse sand is used
 Sand having fine, rounded grains can be closely packed and forms a
smooth surface. Although fine-grained sand enhances mould strength.
12

4. Thermal stability:
The sand adjacent to the metal is suddenly heated and undergoes
expansion. If the mould wall is not dimensionally stable under rapid heating,
cracks, buckling and flacking off sand may occur.
5. Refractoriness:
 Refractoriness is the property of withstanding the high temperature
condition moulding sand with low refractoriness may burn on to the
casting
 It is the ability of the moulding material to resist the temperature of the
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The refractoriness of the Silica sand is highest.
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6. Collapsibility:
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The moulding sand should collapse during the contraction of the
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solidified casting it does not provide any resistance, which may result in cracks
in the castings. Besides these specific properties the moulding material should
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be cheap, reusable and should have good thermal conductivity
7. Adhesiveness:
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It is the important property of the moulding sand and it is defined as the
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sand particles must be capable of adhering to another body, then only the sand
g.n
should be easily attach itself with the sides of the moulding box and give easy
of lifting and turning the box when filled with the stand.
8. Reusability: et
Since large quantities of sand are used in a foundry it is very important
that the sand be reusable otherwise apart from cost it will create disposal
problems
11. Easy of preparation and control:
Sand should lend itself to easy preparation and control by mechanical
equipment.
13

12. Conductivity:
Sand should have enough conductivity to permit removal of heat from
the castings.
2. What are the allowances given while making pattern Explain.
(Dec-2009, 2010, 2012 May-2010, 2013)
A Pattern is always made larger than final casting because it carries
certain allowances due to metallurgical and mechanical reasons.
 Shrinkage allowance
 Draft allowance
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 Shake allowance
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SHRINKAGE ALLOWANCE:
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 Almost all the metals used in the casting work shrink or contract during
cooling from pouring temperature to room temperature.
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 This contraction takes places in three forms i.e
 Liquid contraction
 Solidifying contraction
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 Solid contraction rin
 To compensate liquid and solidifying contraction, gates and riser areg.n
provided in the mould , whereas for solid contraction adequate
allowances are provided on the pattern
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 the different metals shrink at different rates because shrinkage is the
metal property, hence corresponding allowances are also different
 For Aluminium permissible shrinkage allowance is 17 mm/metre
DRAFT ALLOWANCE:
 Withdrawing the pattern from the sand mould, the vertical faces of the
pattern are in continual contact with the sand, which may damage the
mould cavity.
14

 To reduce the chances of this happening the vertical faces of the pattern
are always tapered from the parting line.
 Suggested draft values for wood pattern are outer 0.25 to 3.0 degree. and
10 mm to 25 mm per metre on external surfaces and 40mm to 65 mm on
internal surface.
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FINISH ALLOWANCE: sy E
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 Extra material is to be provided which is to be subsequently removed by
machining or cleaning process.
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 Suggested machining allowance or pattern for non ferrous metal up to 3
mm
 But 2mm allowance was provided on pattern. rin
SHAKE ALLOWANCE: g.n
 Before withdrawal from the sand mould
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 To enlarge the mould cavity slightly
 Since it enlarges the final casting made
 It is desirable that the original pattern dimensions should be reduced to
account for this increase.
DISTORTION ALLOWANCE:
 Distortion allowance applies only to those castings of irregular shape or
U & V shape
 Which are distorted in the process of cooling because of metal shrinkage
15

 the amount of distortion allowances varies from 2mm to 20 mm as per

size shape and casting material
3. With suitable sketches, explain the various steps of investment casting
Process. What are its advantages? (May-2010 to 2015 & Dec-2010 to 2017)
The investment casting process begins with the production of wax
replicas of the desired castings. These replicas, called patterns, are injection
molded in metal dies. A pattern must be manufactured for each casting to be
produced. A number of patterns (depending on size and complexity) are
attached to a central wax stick, or sprue, to form a casting cluster, or assembly.
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After some initial pre-dips, which thoroughly clean the wax, the assemblies are
immersed, or “invested,” into a liquid ceramic slurry, and then into a bed of
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extremely fine sand to form a shell. The first critical layers are often applied by
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hand. Between each layer the ceramic is allowed to dry. The later, heavier
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layers are often applied by automated equipment or special shell building
robots. Enough layers must be applied to build a shell strong enough to
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withstand subsequent operations. After the shell is completely dry, the wax is
mold, which exactly matches nee

melted out in a high pressure steam autoclave, leaving a hollow void within the
the shape of the assembly.
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Prior to casting, the shells are fired in an oven where intense heat burns out any
remaining wax residue and prepares the mold for the molten metal. In the
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conventional gravity pouring method, metal is poured into the shell through a
funnel shaped pour cup and flows by gravity down the sprue channel, through et
the gates and into the part cavities. As the metal cools, the parts, gates, sprue
and pouring cup become one solid casting.
After the casting has cooled, the ceramic shell is broken off and the parts
are cut from the sprue using a high speed friction saw. After minor finishing
operations, the castings, which are identical in configuration to the wax
patterns which shaped them, are ready for certification and shipment to the
customer.
16

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Advantages .Ea
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 Parts of great complexity and intricacy can be cast
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 Close dimensional control and good surface finish
 Wax can usually be recovered for reuse
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Disadvantages
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 Many processing steps are required
 Relatively expensive process g.n
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4. Explain in detail the working principle of centrifugal casting (May-2011,
2012, 2013& 2015 Dec-2013& Nov/Dec- 2016)
Casting, or reforming materials by heating, melting and molding, can be
traced back in history six thousand years. As civilization progressed and the
use of metals became more advanced, the technology of casting metals
advanced as well. As foundry industries began to demand higher yields and
better physical properties from cast metal products, casting processes became
more specialized.
17

The centrifugal casting method was developed after the turn of the
20th century to meet the need for higher standards.
Spinning molds generate centrifugal force on molten metal to position the
metal within a mold. As the molten metal solidifies from the outside in, a
casting with dense, close grain structure is created. As a result of close grain
structure the centrifugal process offers products with better physical properties
than castings made using the static casting method. Other advantages of
products made by the centrifugal process are:
 Smoother Surface
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
Lighter Weight
Thinner Walls
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Combining proper mold design, mold coatings, mold spinning speeds,
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pouring speeds, cooling rates and metal chemistry results in castings with
higher yields, fewer impurities and greater strength.
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Advantages
 Formation of hollow interiors in cylinders without cores

 Less material required for gate
 Fine grained structure at the outer surface of the casting free of gas and
shrinkage cavities and porosity
18

Disadvantages
 More segregation of alloy component during pouring under the forces of

rotation
 Contamination of internal surface of castings with non-metallic
inclusions
 Inaccurate internal diameter
5. Explain in detail the working principle Shell moulding process, product

and applications. (Dec-2013 &Dec-2015)
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Steps in shell-moulding:
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Shell-mould casting yields better surface quality and tolerances. The
process is described as follows the 2-piece pattern is made of metal (e.g.
aluminum or steel), it is heated to between 175°C - 370°C, and coated with a
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lubricant, e.g. silicone spray. Each heated half-pattern is covered with a
mixture of sand and a thermoset resin/epoxy binder. The binder glues a layer of
sand to the pattern, forming a shell. The process may be repeated to get a
thicker shell. The assembly is baked to cure it. The patterns are removed, and
the two half- shells joined together to form the mould; metal is poured into the
mould. When the metal solidifies, the shell is broken to get the part. Smoother
cavity surface permits easier flow of molten metal and better surface finish on
casting.
19

Advantages
 Better surface finish
 Better dimensional tolerances.
 Reduced Machining.
 Less foundry space required.
 Semi skilled operators can handle the process.
 The process can be mechanized.
Disadvantages
 The raw materials are relatively expensive.
ww  The process generates noxious fumes which must be removed.

 The size and weight range of castings is limited.
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Applications
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 Crankshaft fabrication
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 Steel casting parts, fittings
 Moulded tubing fabrication
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 Hydraulic control housing fabrication
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 Automotive castings (cylinder head and ribbed cylinder
fabrication
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Part - C
1. Describe the operation of cupola furnace for melting cast iron? (Dec- g.n
2009, May-2011 & Dec-2014 &2015) et
 For many years, the cupola was the primary method of melting used in
iron foundries. The cupola furnace has several unique characteristics
which are responsible for its widespread use as a melting unit for cast
iron.
 Cupola furnace is employed for melting scrap metal or pig iron for
production of various cast irons. It is also used for production of
nodular and malleable cast iron. It is available in good varying sizes.
20

The main considerations in selection of cupolas are melting capacity,

diameter of shell without lining or with lining, spark arrester.
Shape
A typical cupola melting furnace consists of a water-cooled vertical
cylinder which is lined with refractory material.
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Construction
 The construction of a conventional cupola consists of a vertical steel
shell which is lined with a refractory brick.
 The charge is introduced into the furnace body by means of an opening
approximately half way up the vertical shaft.
21

 The charge consists of alternate layers of the metal to be melted, coke

fuel and limestone flux.
 The fuel is burnt in air which is introduced through tubers positioned

above the hearth. The hot gases generated in the lower part of the shaft
ascend and preheat the descending charge.
Working of Cupola Furnace

 The charge, consisting of metal, alloying ingredients, limestone, and
coal coke for fuel and carbonization (8-16% of the metal charge), is fed
ww in alternating layers through an opening in the cylinder.

 Air enters the bottom through tubers extending a short distance into the
w .Ea
interior of the cylinder. The air inflow often contains enhanced oxygen
levels.
sy E
 Coke is consumed. The hot exhaust gases rise up through the charge,
ngi
preheating it. This increases the energy efficiency of the furnace. The
charge drops and is melted.
nee
 Although air is fed into the furnace, the environment is a reducing one.
rin
Burning of coke under reducing conditions raises the carbon content of
the metal charge to the casting specifications.
 As the material is consumed, additional charges can be added to theg.n
furnace.
 A continuous flow of iron emerges from the bottom of the furnace.
et
Advantages
 It is simple and economical to operate.
 High melt rates
 Ease of operation
 Adequate temperature control
 Chemical composition control
 Efficiency of cupola varies from 30 to 50%.
22

 Less floor space requirements comparing with those furnaces with same
capacity.
Limitations
 Since molten iron and coke are in contact with each other, certain
elements like si, Mn are lost and others like sulphur are picked up. This
changes the final analysis of molten metal.
 Close temperature control is difficult to maintain
Application
 Cast-iron
ww
2. Write down note on classification of Casting defects causes and remedy.
w
(Nov/Dec-2010), (May-2011), (Dec-2012, 2013,&2015) (June-2014&2015&
Nov/Dec- 2016 )
.Ea
Si
no
Defects
sy E Possible causes Effective remedies
1
moulding sand ngi
 Excess moisture in the  control moisture
content
chaplets used. nee

 Rust and moisture n chills  use clean and rust
free chills, chaplet
Blow holes  Cores are not sufficiently
baked rin
 bake the cores
properly
 Moulds are not adequately
vented g.n
 Provide adequate
venting in moulds
2 

High temperature of pouring.
Gas discoed in metal charge
and cores
temperature
et
 Regulating pouring
 less amount of flux  Control metal

Porosity  slow solidification composition.
 Increase flux
proportion
 Modify gating and
risering
3  faulty gating and risering and  ensure proper
improper chilling directional
Shrinkage solidification by
modifying gating
risering and chilling
23

4  faulty gating system  Modify gating system

 Faulty pouring  Improve pouring to
Inclusions  soft ramming of mould minimize turbulence
 Rough handling of core and  Provide harder
mould ramming
 take care in handling
5  Lack of core collapsibility  Improve core
 Lack of mould collapsibility collapsibility
Hot tears
 Faulty design  Improve mould
or hot  Hard ramming of mould collapsibility
cracks  Modify the design
 Provide softer
ramming
6  Lack of fluidity in molten  adjust proper pouring
ww Misrun and
cold shuts
metal
 Faulty design and gating
temperature
 Modify the design
7 w .Ea Low strength of mould and

core
and gating system
 Improve mould and
core strength
 faulty gating  Modify the gating
Cuts and
washes
sy E
 Lack of binders in facing and
core sand
system
 Add more binds
(Scabs)
ngi
8
nee
 Worn out or bent clamping  repair or replace the
 pins
 Misalignments of two halves of rin pins
 Replace dowel
Mismatch
pattern
 Improper location and support
g.n
causing misalignment
 Provide adequate
of core
 faulty core boxes
et
core support and
locate it properly
 Replace the core
boxes
24

ww
w.Ea
sy E
ngi
nee
rin
g.n
et
25

UNIT II - METAL JOINING PROCESSES

PART-A
1. What is meant by Nuggest in Electrical Resistance welding?

(Nov/Dec 2014)
The point at which the molten metal is created for short period of time
due to maximum heat generation is called nuggest.
2. Write short notes on thermit welding. (Nov/Dec 2012,13)

It is a fusion welding process in which the weld is effected by pouring
ww
superheated liquid thermit steel around the parts to be united.
w
3. What is meant by “carburising flame” in gas welding?
.Ea (Nov/Dec 2012)
sy E
Gas welding is done by burning a combustible gas with air or oxygen in a
concentrated flame of high temperature. In which there is an excess of
ngi
acetylene is needed the flame produced is called carburising flame.
Brazing
nee
4. Write the difference between brazing and soldering.(May/Jun 2014,15)
Soldering
The process of joining two metals by rin
The process of joining two metals by
using filler metal (fusible alloy) is
g.n
using a harder filler metal (spelter) is
known as brazing. The filler metal
having liquid temperature is above
known as soldering. The filler metal
having liquid temperature is below et
4270 C. 4270 C.
5. What are the functions of flux in welding electrode?

(May/Jun 2010, 12, Nov/Dec 2013, 14)
The functions of flux are
 To remove the impurities and oxides present on the surfaces of

metal.
 To obtain a satisfactory bond.
26

6. Name various causes for the defect porosity in welding. (May/Jun 2015)
 Presence of gases in the metal

 Moisture in the flux
 Rust on the welded edges or filler material
7. Differentiate fission welding from fusion welding. (May/Jun 2010)
Fusion welding Fission welding

The metals at the joint is heated to a The metal parts are heated to a plastic
molten state and allowed to solidify. state and are pressed together to make
ww
It is also called non pressure welding. the joint. It is also called pressure
w
E.g: Gas welding , Arc welding
.Ea
welding.
E.g: Solid state welding
sy E
8. Sketch the different types of oxyacetylene flames. (May/Jun 2014)
ngi
Types of flame
nee Sketch of flame
rin
Neutral flame
g.n
et
Oxidizing flame
27

Carburizing flame
9. What is the minimum distance maintained between two successive spot

welds made by resistance welding? Why? (May/Jun 2013)
ww The minimum distance 150 mm and maximum distance between two
w
securing points 300 mm should be maintained two successive spot welds or the
.Ea
acceptable distance is 16 times of thickness of metal to be welded because the
sy E
shunt current flowing through already formed weld spot reduces the efficiency
of the welding process.
ngi
welding. nee
10. Write short notes on transferred and non transferred in plasma arc
(May/Jun 2013)
Transferred type:
rin
g.n
In transferred type, the tungsten electrode is connected to the negative
terminal and the work piece is connected to the positive terminal. An electric
arc is maintained between the electrode and the work piece heats a co-axial et
flowing gas and maintains it in a plasma state.
Non- Transferred type:
In this type, the power is directly connected with the electrode and the
torch of nozzle. The electrode carries the same current. Thus the ionizing is at
high velocity gas that is strewing towards the work piece.
28

11. Mention the application of friction welding. (May/Jun 2010)
 Aerospace industry.
 Automobile industry.
12. Define the term “electrode” and mention its major classifications.
(Nov/Dec 2011)
Electrode is a solid rod in arc welding process to produce electric arc by

passing the current through the work piece and electrode for melting the
surfaces or edges are joined without applying external force.
ww
Types of Electrode:
w (i) Consumable electrodes
.Ea
 Bare electrodes
sy E
 Lightly coated electrodes
 Heavily coated electrodes
(ii)
ngi
Non -Consumable electrodes
nee
13. What is the principle of resistance welding? (Nov/Dec 2009)
rin
The two metal parts to be joined are heated to a plastic state by their
resistance to the flow of electric current and the mechanical pressure is used to
complete the weld. g.n
14. How can slag inclusions in welding be avoided? (May/Jun 2008) et
 Avoid multi layer welding
 Reduce arc length
 Increase electrode angle
 Avoid using large electrode
15. What are the diameters and length of electrodes available in the
market? (Nov/Dec 2009)
 Standard lengths of electrodes are 250 mm, 300 mm and 450 mm.
 Standard diameters of electrodes are 1.6, 2, 2.5, 3.2, 4, 5,6,7,8 and 9mm
29

PART - B
1.Explain with neat sketch the components of oxy acetylene gas welding
equipment. (Nov/Dec 2014)
Gas cylinders:
Gas welding, ahead of oxygen and acetylene are used. These two gases
are stored in separate cylinders. The standard colour for oxygen cylinder is
black. The oxygen is stored in the cylinder at a pressure of 125 to 140 kg/cm2.
The standard colour for acetylene cylinder is maroon. The acetylene is stored in
the cylinder at a pressure of
ww
16 kg/cm2. Acetylene cylinder is fitted with a fusible plug to avoid explosion.
w
Pressure regulators:
.Ea
Each cylinder is fitted with a pressure regulator. These regulators are
used to reduce and control the working pressure of the gases. The working
sy E
pressure of oxygen is 0.7 to 2.8 kg/cm2. The working pressure of acetylene is
0.07 to 1.03 kg/cm2.
Pressure gauges: ngi
nee
There are four pressure gauges provided in which two are placed on the
rin
oxygen cylinder regulators and two on acetylene cylinder regulators. Among
g.n
two pressure gauge, one is for showing the cylinder pressure. The other one is
for showing the working pressure for welding.
Hoses:
The regulator of each cylinder is connected to the torch through two
et
long hoses. It should be flexible, strong, desirable, non-process and light.
Welding torch:
Oxygen and acetylene gases enter the torch through the hose in separate
passages. Both the gases are mixed in the mixing chamber of the torch. When it
is ignited, a flame will be produced at the tip of the torch called nozzle. There
are two control valves on the welding torch. They are used to control the
quantity of oxygen and acetylene gases to adjust the flame.
30

ww
w .Ea
sy E
ngi
Goggles:
nee
The welding goggles are used to protect eyes from the flame heat, and
ultraviolet and infrared rays.
rin
Welding gloves:
g.n
Gloves are used to protect hand from the injury causing by heat and
metal splashes. et
2. Describe the process of Electro slag welding and identify their major
applications. (Nov/Dec 2014)
Electro slag welding process which produces coalescence through
electrically melted flux which melts both the filler metal and the surface of the
work piece to be melted. Welding is initiated on a starting block at the bottom
of the vertically positioned joint. Flux poured around the electrode is converted
to slag that floats on a layer of molten metal confined in the joint by water
cooled copper shoes that slides on the sides. The heat of the fusion is provided
31

by resistance heating in the slag. The welding dams and head move upward as
weld metal solidifies and new metal is fed in by the wire electrodes.
ww
w The consumable wire electrode may be solid or flux coated but most of
.Ea
the shielding is provided by an argon and CO2 gas mixture injected into the
sy E
gap. The heat is furnished by an electrical arc between the electrode and metal
pool. It is used particularly for thick plates and structures for turbine shafts,
boiler parts.
ngi
Advantages of Electro slag welding:
 High deposition rate. nee
 Low slag consumption rin
 Low distortion
g.n
 Unlimited thickness of work piece
Disadvantages of Electro slag welding:

et
 Coarse grain structure of the weld
 Low toughness of the weld
 Vertical position possible only
Applications:
 Construction of bridges, pressure vessels,
 Construction of thick walled and large diameter pipes
 Construction of thick storage tanks and ships.
32

3. What is the principle of thermit welding? Explain the same with a neat
sketch of the welding arrangement. (May/Jun 2012& 2017)
It is a fusion welding process in which the weld is effected by pouring
superheated liquid thermit steel around the parts to be united. The thermit
process for welding metal is based on the chemical reaction between finely
divided aluminium and iron oxide.
8Al + 3Fe3O4 = 4Al2 O3 + 9Fe
During the reaction, the oxygen leaves the iron oxide and combines with
aluminum, producing aluminum oxide, or slag, and superheated thermit steel.
ww The thermit is a mixture of finely divided aluminium and iron oxide, the
ratio by weight being approximately three parts of iron oxide to one part of
w
aluminium. The mixture placed in a refractory – lined crucible, is ignited with
.Ea
the aid of a highly inflammable powder composed largely of barium peroxide.
sy E
The temperature produced by the thermit reaction is approximately 3000 0 C or
about twice the temperature of the melting point steel.
ngi
nee
rin
g.n
In making pressure welds by the thermit process, a pattern of wax is
shaped around the parts to be welded. A sheet iron box is placed around the et
wax pattern and the space between the pattern and box is filled and rammed
with sand. Pouring and heating gates, and risers, are cut in the sand and a flame
is directed into the heating opening. The wax pattern melts and drains out but
the heating is continued to raise the temperature of the parts to be welded. This
preheating is done before the liquid metal is poured into the mould in order to
prevent chilling of the steel. Then the burner or torch is removed, and the
preheating gate is plugged with sand. The superheated metal produced by the
thermit reaction in a crucible is poured into the mould surrounding the surfaces
33

to be welded. After the welding temperature is reached mechanical pressure is

applied to complete the weld.
Applications:
 Joining of railroad rails.
 Repair of cracks in large steel castings and forgings.
 Weld surface is often smooth enough that no finishing is
required.
Advantages of thermit welding:
 No external power source is required.
ww  Very large heavy section parts may be joined.

Disadvantages of thermit welding:
w  Only ferrous parts may be welded.

.Ea
 Slow welding rate
sy E
 It causes distortion in the weld region.
ngi
4. Explain Resistance seam welding with neat sketch. (Nov/Dec 2013)
nee
Seam welding is a method of making a continuous joint between two
rin
over lapping pieces of sheet metal. The normal procedure for making seam
g.n
welding is to place the work between the wheels which serve as conductors for
producing continuous welds. As pressure is applied, the drive started and the
welding current switched on. Then at the same time, the over lapping surfaces
of metal are forced together as fast as they are heated.
et
34

A coolant is applied to conserve the electrodes and cool the work rapidly
to speed the operation. The materials that may be seam welded include most of
those that may be spot welded. Steel plates 10 mm thick have been seam
welded to hold about 200 kg/cm2 pressure.
Advantages of Resistance seam welding:
 No filler metal required
 High production rates possible
 Lends itself to mechanization and automation
 Lower operator skill level than for arc welding
ww  Good repeatability and reliability

Disadvantages of Resistance seam welding:
w  High initial equipment cost

.Ea
 Limited to lap joints for most seam welding processes
sy E
5. Explain Friction stir welding with neat sketch. (Nov/Dec 2013& 2016)
ngi
The frictional energy generated when two bodies slide on each other is
nee
transformed into heat; when the rate of movement is high and the heat is
contained in a narrow zone, welding occurs.
rin
g.n
et
In practically one part is firmly held while the other is rotated under
simultaneous application of axial pressure. The temperature rises, partially
formed welded spots are sheared, surface films are disrupted, and the rotation is
suddenly arrested when the entire surface is welded. Some of the softened
35

metal is squeezed out into a flash, but it is not fully clear whether melting takes
place. The heated zone being very thin, dissimilar metals are easily joined.
Limitations:
 At least one of the parts must be rotational
 Flash must usually be removed
 Upsetting reduces the part lengths (which must be taken into
consideration in product design)
Applications:
 Shafts and tubular parts
ww  Industries: automotive, aircraft, farm equipment, petroleum

and natural gas
w .Ea
6. Explain the arc welding process with neat sketch. (May/Jun 2015)
sy E
In arc welding process, the heat is developed by an electric arc. The arc
is produced between an electrode and the work. It is the process of joining two
ngi
metal pieces by melting their edges by an electric arc. In this welding, the
nee
electrical energy is converted into heat energy. The electrode and work piece
are brought near to each other with a small gap of 3mm approximately. Then
rin
the current is passed through the work piece and electrode to produce an
electric arc.
g.n
et
The work piece is melted by the arc. The electrode is also melted and
hence, both the work pieces become a single piece without applying external
36

pressure. The temperature of arc is about 50000 C to 60000 C. the electrode

supplies additional filler metal into the joints and is deposited along the joint. A
transformer is used for supplying the current. To obtain better depth of fusion,
the electrode is kept at 700 inclinations to the vertical.
Advantages:
 Most efficient way to join metals
 Lowest-cost joining method
 Affords lighter weight through better utilization of materials
 Joins all commercial metals
ww  Provides design flexibility

Disadvantages:
w  Manually applied, therefore high labor cost.

.Ea
 Need high energy causing danger
sy E
 Not convenient for disassembly.
 Defects are hard to detect at joints.
ngi
Part - C
nee
1. Describe the ultrasonic welding process with neat diagram.
rin
(May/Jun 2015)
g.n
Ultrasonic welding is the joining or reforming of thermoplastics through
the use of heat generated from high-frequency mechanical motion. It is
accomplished by converting high-frequency electrical energy into high-
frequency mechanical motion. That mechanical motion, along with applied
et
force, creates frictional heat at the plastic components' mating surfaces (joint
area) so the plastic material will melt and form a molecular bond between the
parts.
The two thermoplastic parts to be assembled are placed together, one on
top of the other, in a supportive nest called a fixture. A titanium or aluminum
component called a horn is brought into contact with the upper plastic part. A
controlled pressure is applied to the parts, clamping them together against the
fixture. The horn is vibrated vertically 20,000 Hz (20 kHz) or 40,000 Hz (40
37

kHz) times per second, at distances measured in thousandths of an inch

(microns), for a predetermined amount of time called weld time. Through
careful part design, this vibratory mechanical energy is directed to limited
points of contact between the two parts.
ww
w .Ea
The mechanical vibrations are transmitted through the thermoplastic
sy E
materials to the joint interface to create frictional heat. When the temperature at
the joint interface reaches the melting point, plastic melts and flows, and the
ngi
vibration is stopped. This allows the melted plastic to begin cooling. The
nee
clamping force is maintained for a predetermined amount of time to allow the
parts to fuse as the melted plastic cools and solidifies. Once the melted plastic
rin
has solidified, the clamping force is removed and the horn is retracted. The two
g.n
plastic parts are now joined as if molded together and are removed from the
fixture as one part.
Advantages: et
 Fast, economical and easily automated.
 Mass production can be made.
 Increased flexibility and versatility.
 Possibility to join large structures.
Disadvantages:
 Large joints cannot be weld in a single operation.
 Specifically designed joints are required.
 Tooling costs for fixtures are high.
38

2. What is meant by welding defect? Explain any five welding defects.

(May/Jun 2010 & 2017)
The defects in the weld can be defined as irregularities in the weld metal
produced due to incorrect welding parameters or wrong welding procedures or
wrong combination of filler metal and parent metal. Weld defect may be in the
form of variations from the intended weld bead shape, size and desired quality.
1. Cracks
Cracks may be of micro or macro size and may appear in the weld metal
or base metal or base metal and weld metal boundary. Different categories of
ww
cracks are longitudinal cracks, transverse cracks or radiating/star cracks and
cracks in the weld crater. Cracks occur when localized stresses exceed the
w
ultimate tensile strength of material. These stresses are developed due to
.Ea
shrinkage during solidification of weld metal.
sy E
ngi
nee
2. Porosity
rin
g.n
Porosity results when the gases are entrapped in the solidifying weld
metal. These gases are generated from the flux or coating constituents of the
electrode or shielding gases used during welding or from absorbed moisture in et
the coating. Rust, dust, oil and grease present on the surface of work pieces or
on electrodes are also source of gases during welding. Porosity may be easily
prevented if work pieces are properly cleaned from rust, dust, oil and grease.
39

3. Solid Inclusion
Solid inclusions may be in the form of slag or any other nonmetallic

material entrapped in the weld metal as these may not able to float on the
surface of the solidifying weld metal. During arc welding flux either in the
form of granules or coating
ww
after melting, reacts with the molten weld metal removing oxides and other
impurities in the form of slag and it floats on the surface of weld metal due to
w
its low density.
.Ea
4. Lack of Fusion and Inadequate or incomplete penetration:
sy E
Lack of fusion is the failure to fuse together either the base metal and
ngi
weld metal or subsequent beads in multipass welding because of failure to raise
the temperature of base metal or previously deposited weld layer to melting
nee
point during welding. Lack of fusion can be avoided by properly cleaning of
rin
surfaces to be welded, selecting proper current, proper welding technique and
correct size of electrode.
g.n
et
5. Imperfect Shape : Imperfect shape means the variation from the desired
shape and size of the weld bead. During undercutting a notch is formed either
on one side of the weld bead or both sides in which stresses tend to
concentrate and it can result in the early failure of the joint. Main reasons for
undercutting are the excessive welding currents, long arc lengths and fast
travel speeds.
40

UNIT III – METAL FORMING PROCESS
PART- A
1. What is meant by closed die forging? (Nov/Dec 2010)

In closed die forging closed impressions rather than open face of flat
dies are used. It utilizes closed impression die o obtain the required
shape of the component.
2. Mention the different types of shape rolling operations.
(Nov/Dec 2010)
a) Ring rolling
ww b) Thread rolling
w
3. Distinguish between hot working and cold working of metals.
.Ea (May/Jun 2012)
sy E
Hot working Cold working
in the metal. ngi

Residual stresses are not developed Residual stresses are developed in
the metal.
No hardening of metal takes place nee Metal gets work hardened
Due to oxidation and scaling, poor rin

Cold work parts carry better
surface finish is obtained. surface finish g.n
4. Define extrusion, as manufacturing process. (May/Jun 2012)
The extrusion process consists of compressing a metal inside a chamber
et
o force it out through a small opening which is called as die.
5. Working on the metal lead at room temperature is considered to be
hot working. (Nov/Dec 2010)
Working on the metal lead at room temperature is considered to be hot
working because,
i) Lead has low melting point of 327o C
ii) It is poisonous.
41

6. List two advantages of cold extrusion over hot extrusion.

(Nov/Dec 2010)
i) High speed of operation
ii) Product uniformity
iii) No wastage
7. What is meant by fullering? (May/Jun 2013)
Fullering is also called as spreading. Fullering the metal along the length
of the workpiece is done by working separate sections. In this, the axis
of the workpiece is positioned perpendicular to the width of the flat die.
ww
8. Define upsetting and drawing down in forging operation.
(May/Jun 2013)
w  Upsetting is a process through which the cross-section of a metal
.Ea
piece is increased with a corresponding increase in its length.
sy E
 Drawing down is employed when a reduction in thickness, which
of a bar is desired with a corresponding increase in its length.
ngi
9. What are the various forming process? (April/May 2015)
i)
ii)
Bulk deformation process
Sheet metal working processesnee
10. Name various defects in parts produced by drawing. rin
g.n
(April/May 2015)
i)
ii)
Surface defects
Internal structural defects et
iii) Other defects
11. Why is drop forging called so? (Nov/Dec 2014)
When the rolls are released, the ram will fall down and produce a
working stroke, then it is said to be drop forging.
12. What does angle of bite in rolling mean?
(Nov/Dec 2014) & (Nov/Dec 2015)
The angle subtended by the centre of the roll with radial force in rolling
operations is called angle of bite or angle of contact.
42

13. Differentiate extrusion and forging. (Nov/Dec 2014)

Extrusion Forging
The heated metal is compressed The heated metal bar is held inside
and forced through a suitable the solid die and the force is given
shaped die. to the punch. So, the punch will
squeeze the heated metal to the
shape of the die cavity.
Most of the metals are extruded in Both hot and cold conditions are
ww hot conditions only. preferred.
Mainly rollers are used to extrude Either hammer or press tool is
w .Ea
the object. used to apply the pressure.
sy E
ngi
14. Sketch different types of rolling mills. (May/Jun 2014)
nee
rin
g.n
et
43

15. Why is the surface finish of a rolled product better in cold rolling
than hot rolling? (May/Jun 2016)
Hot rolling Cold rolling
Poor surface finish with scale on Smooth and oxide free surface can
it. obtained.
PART- B
1. Describe the principle of hot and cold working processes. Compare

ww them. (Nov/Dec 2010, May/Jun 2013, Nov/Dec 2014, April/May
w2015, Nov/Dec 2014)
Hot Working: .Ea

sy E
Plastic deformation of metal carried out at temperature above the
ngi
recrystallization temperature, is called hot working. Under the action of
nee
heat and force, when the atoms of metal reach a certain higher energy
level, the new crystals start forming. This is called recrystallization.
rin
When this happens, the old grain structure deformed by previously
carried out mechanical working no longer exist, instead new crystals
which are strainfree are formed. In hot working, the temperature at g.n
which the working is completed is critical since any extra heat left in the
material after working will promote grain growth, leading to poor
et
mechanical properties of material.
In comparison with cold working, the advantages of hot working are

1. No strain hardening
2. Lesser forces are required for deformation
3. Greater ductility of material is available, and therefore more
deformation is possible.
44

4. Favorable grain size is obtained leading to better mechanical

properties of material
5. Equipment of lesser power is needed
6. No residual stresses in the material.
Some disadvantages associated in the hot-working of metals are:
1. Heat energy is needed
2. Poor surface finish of material due to scaling of surface
3. Poor accuracy and dimensional control of parts
4. Poor reproducibility and interchangeability of parts
ww 5. Handling and maintaining of hot metal is difficult and troublesome

6. Lower life of tooling and equipment.
w
Cold Working:
.Ea
sy E
Plastic deformation of metals below the recrystallization temperature is
known as cold working. It is generally performed at room temperature. In some
ngi
cases, slightly elevated temperatures may be used to provide increased ductility
nee
and reduced strength. Cold working offers a number of distinct advantages, and
for this reason various cold-working processes have become extremely
rin
important. Significant advances in recent years have extended the use of cold
forming, and the trend appears likely to continue.
g.n
In comparison with hot working, the advantages of cold working are
1. No heating is required
et
2. Bettter surface finish is obtained
3. Better dimensional control is achieved; therefore no secondary machining is

generally needed.
4. Products possess better reproducibility and interchangeablity.
5. Better strength, fatigue, and wear properties of material.
45

6. Directional properties can be imparted.
7. Contamination problems are almost negligible.
Disadvantages associated with cold-working processes are:
1. Higher forces are required for deformation.
2. Heavier and more powerful equipment is required.
3. Less ductility is available.
4. Metal surfaces must be clean and scale-free.
ww
5. Strain hardening occurs (may require intermediate annealing).
6. Undesirable residual stresses may be produced Cold forming processes, in
w
general, are better suited to large-scale production of parts because of the cost
.Ea
of the required equipment and tooling.
sy E
2. Explain the working principle of wire and tube drawing processes with
neat sketches. (Nov/Dec 2010, May/Jun 2012, May/Jun 2013, Nov/Dec
2014, Nov/Dec 2015)
ngi
WIRE DRAWING
nee
rin
Wire drawing is primarily the same as bar drawing except that it involves
smaller – diameter material that can be coiled. It is generally performed as a
continuous operation on draw bench like the one shown in Fig. g.n
et
46

Large coil of hot rolled material of nearly 10 mm diameter is taken and

subjected to preparation treatment before the actual drawing process. The
preparation treatment for steel wire consists of:
 Cleaning. This may be done by acid pickling, rinsing, and drying. Or, it
may be done by mechanical flexing.
 Neutralization. Any remaining acid on the raw material is neutralized by
immersing it in a lime bath. The corrosion protected material is also
given a thin layer of lubricant.
To begin the drawing process, one end of coil is reduced in cross section
ww
upto some length and fed through the drawing die, and gripped. A wire
drawing die is generally made of tungsten carbide and has the configuration
w
shown in fig. for drawing very fine wire, diamond die is preferred.
.Ea
sy E
ngi
nee
rin
g.n
Small diameter wire is generally drawn on tandem machines which
et
consist of a series of dies, each held in a water – cooled die block. Each die
reduces the cross section by a small amount so as to avoid excessive strain in
the wire. Intermediate annealing of material between different states of wire
may also be done, if required.
47

TUBE DRAWING
The diameter and wall thickness of tubes that have been produced by
extrusion or other processes can be reduced by tube drawing process. The
process of tube drawing is similar to wire or rod drawing except that it usually
requires a mandrel of the requisite diameter to form the internal hole. Tubes as
large as 0.3 m in diameter can be drawn.
ww
w .Ea
sy E
ngi
This is also called as tube sinking. In tube sinking method there is no
nee
control over the inner diameter and wall thickness of tube. To overcome this
drawback, mandrels are used in the process. In this method, the mandrel is
rin
fixed and attached to a long support bar to produce inside diameter and wall
thickness during the process.
g.n
3. With neat sketches, explain the smith forging operations. (Nov/Dec 2012,
April/May 2015 & Dec-2016) et
1. Upsetting
This is applied to increase the cross sectional area of the stock at the expanse of
the length. To achieve the length of upsetting force is applied in a direction
parallel to the length axis, For example forming of a bolt head.
48

2. Fullering
It a similar to material cross-section is decreased and length increased.
To do this; the bottom fuller is kept in angle hole with the heated stock over the
fuller .the top fuller is then kept above the stock and then with the sledge
hammer, and the force is applied on the top fuller.
ww 3. Drawing:
w This is the operation in which metal gets elongated with a reduction in

.Ea
the cross sedation area. For this, a force is to be applied in a direction
sy E
perpendicular to the length axis.
ngi
nee
rin
g.n
4. Edging:It is a process in which the metal piece is displaced to the
desired shape by striking between two dies edging is frequently as primary
et
drop forging operation.
49

5.Bending:
Bending is very common forging operation. It is an operation to give a

turn to metal rod or plate. This is required for those which have bends shapes.
5. Punching:
ww
It is a process of producing holes in motel plate is placed over the hollow
w
cylindrical die. By pressing the punch over the plate the hole is made.
.Ea
sy E
ngi
nee
rin
g.n
7: Forged welding: It It is a process of joining two metal pieces to increase the
length. By the pressing or hammering then when they are at for ging
temperature.Itis performed in forging shop and hence is called forged welding.
et
8:Cutting:
It is a process in which a metal rod or plate cut out into two pieces, with the
help of chisel and hammer, when the metal is in red hot condition.
9:Flating and setting down:
Fullering leaves a corrugated surface on the job. Even after a job is forged
into shape with a hammer, the marks of the hammer remains on the upper
50

surface of the job. To remove hammer marks and corrugation and in order to
obtain a smooth surface on the job, a flatter or set hammer is used.
10. Swaging:
wwSwaging is done to reduce and finish work for desire size and shape, usually
w
either round or hexagonal. For small jobs top and bottom swage pair is
.Ea
employed, where as for large work swage block can be used.
sy E
ngi
nee
rin
g.n
4. With suitable sketches describe indirect and direct extrusion. (Nov/Dec
2012, Nov/Dec 2013, May/Jun 2014, Nov/Dec 2014, April/May 2015)
Extrusion is the process by which long straight metal parts can be

et
produced. The cross-sections that can be produced vary from solid round,
rectangular, to L shapes, T shapes. Tubes and many other different types.
Extrusion is done by squeezing metal in a closed cavity through a tool, known
as a die using either a mechanical or hydraulic press.
Extrusion produces compressive and shear forces in the stock. No tensile

is produced, which makes high deformation possible without tearing the metal.
The cavity in which the raw material is contained is lined with a wear resistant
51

material. This can withstand the high radial loads that are created when the
material is pushed the die.
Cold Extrusion: Cold extrusion is the process done at room temperature or

slightly elevated temperatures. This process can be used for most materials-
subject to designing robust enough tooling that can withstand the stresses
created by extrusion. Examples of the metals that can be extruded are lead, tin,
aluminum alloys, copper, titanium, molybdenum, vanadium, steel. Examples of
parts that are cold extruded are collapsible tubes, aluminum cans, cylinders,
gear blanks. The advantages of cold extrusion are:
ww• No oxidation takes place.
w
• Good mechanical properties due to severe cold working as long as the
.Ea
temperatures created are below the re-crystallization temperature.
sy E
• Good surface finish with the use of proper lubricants.
ngi
Hot Extrusion: Hot extrusion is done at fairly high temperatures,
approximately 50 to 75 % of the melting point of the metal. The pressures can
nee
range from 35-700 MPa (5076 - 101,525 psi). Due to the high temperatures and
rin
pressures and its detrimental effect on the die life as well as other components,
g.n
good lubrication is necessary. Oil and graphite work at lower temperatures,
whereas at higher temperatures glass powder is used.
Typical parts produced by extrusions are trim parts used in automotive and
et
construction applications, window frame members, railings, aircraft structural
parts.
Direct Extrusion or Forward Extrusion
The equipment consists of a cylinder or container into which the heated

metal billet is loaded. One end of the container, the die plate with necessary
opening is fixed. From the other end plunger or ram compresses the metal billet
against the container walls and die plate, thus the forcing it to flow of metal in
the forward direction through the die opening.
52

Acquiring the shape of the opening the extruded metal is then carried by
the metal is then carried b the metal handling system as it comes out of the die.
A dummy block which is a steel disc of about 40mm thick with a diameter
slightly less than container is kept between the hot billet and the ram to protect
it form heat and pressure. In direct extrusion, the problem of friction prevalent
because of the relative motion between heated metal billet and cylinder walls.
To reduce this friction lubricants are to be used. To reduce the damage to
equipment, extrusion is finished quickly and the cylinder is cooled before
further extrusion.
ww
w .Ea
sy E
ngi
nee
rin
g.n
Indirect extrusion or backward extrusion
In order to completely overcome the problem, the backward hot extrusion

et
as shown in figure, in this process the metal is confined fully by the cylinder,
the ram which houses the die also compresses the metal against the container,
forcing it to flow backward to the die in the hollow plunger or ram.
It is termed backward because of the opposite direction of the flow of the

metal. Thus the billet in the container remains stationary and hence produces
no friction. Also the extrusion pressure is not affected by the length. In the
53

extrusion press since the friction is not loss. The figure of the backward
extrusion is shown;
5. With neat sketches, explain the different types of roll sand

arrangements used in the rolling mills. (May/Jun 2012, May/Jun 2014,
Nov/Dec 2015 & May-2017)
Rolling mills may be classified according to the number and arrangement

of the rolls.
(a): Two high rolling mills (b): Three high rolling mills
(c): Four high rolling mills (d): Tandem rolling mills
ww (e): Cluster rolling mills
w .Ea
1: Two high rolling mills
sy E
Two high rolling mills may further classified as
 Reversing mill
 Non reversing mill
ngi
nee
A two high rolling mill has two rolls only.
Two high reversing mill:
rin
In two high reversing rolling mills the rolls rotate ist in one direction and
g.n
then in the other, so that rolled metal may pass back and forth through the rolls
several times. This type is used in pluming and slabing mills and for roughing
work in plate , rail , structural and other mills. et
54

These are more expensive compared to the non reversing rolling mills.
Because of the reversible drive needed.
Two high non reversing mill:
In two high non reversing mills as two rolls which revolve continuously
in same direction therefore smaller and less costly motive power can be used.
However every time material is to be carried back over the top of the mill for
again passing in through the rolls. Such an arrangement is used in mills through
which the bar passes once and in open train plate mill.
ww
w .Ea
sy E
2: Three high rolling mill:
ngi
nee
It consists of a roll stand with three parallel rolls one above the other.
rin
Adjacent rolls rotates in opposite direction. So that the material may be passed
between the top and the middle roll in one direction and the bottom and middle
rolls in opposite one. g.n
In three high rolling mills the work piece is rolled on both the forward
and return passes. First of all the work piece passes through the bottom and
et
middle rolls and the returning between the middle and the top rolls.
55

So that thickness is reduced at each pass. Mechanically operated lifted

tables are used which move vertically or either side of the stand. So that the
work piece fed automatically into the roll gap.
Since the rolls run in one direction only a much less powerful motor and
transmission system is required. The rolls of a three high rolling mills may be
either plain or grooved to produce plate or sections respectively.
3: Four high rolling mill:
It has a roll stand with four parallel rolls one above the other. The top and
ww
the bottom rolls rotate in opposite direction as do the two middle rolls. The two
middle are smaller in size than the top and bottom rolls which are called
w .Ea
backup rolls for providing the necessary rigidity to the smaller rolls.
sy E
ngi
nee
rin
g.n
A four high rolling mill is used for the hot rolling of armor and other plates as
well as cold rolling of plates, sheets and strips.
4: Tandem rolling mills: et

It is a set of two or three stands of roll set in parallel alignment. So that a
continuous pass may be made through each one successively with change the
direction of material.
56

5: Cluster rolling mills:
It is a special type of four high rolling mill in which each of the two
working rolls is backup by two or more of the larger backup rolls for rolling
hard in materials. It may be necessary to employ work rolls of a very small
diameter but of considerable length. In such cases adequate of the working rolls
can be obtained by using a cluster mill.
ww
w .Ea Part - C
sy E
1. a) With neat sketch, explain the working of a Pneumatic hammer for
forging. (May/Jun 2012) ngi
nee
rin
g.n
et
57

Here we have fixed the pneumatic cylinder on the column of the

machine which is fixed on the base table. The forging hammers are fixed at the
end of the pneumatic cylinder piston rod. The pneumatic cylinder is operated
through the pneumatic energy (air). The air stored in a compressor the
compressed air is passed to the pneumatic cylinder with the help of the
solenoid valve.
The solenoid valves are operated through the control unit. The air enters
on port one in the pneumatic cylinder to moves the forging hammer in
downward direction. After the forging operation takes places the forging
ww
hammer will moves in upward direction.
wWhile on the hammer moves in upward direction the port one will release
.Ea
and the air will be forced into the port number two. The two directions are
sy E
controlled by control unit. During the movement the forging hammer forged
the specimen to make it to the required shape and size. After the required
ngi
number of strokes completed the forging process is stopped by the help of the
control unit
nee
rin
1. b) Explain the steps involved in drop forging with neat sketch. (Nov/Dec
2015)
g.n
et
58

This is the operation done in closed impression dies by means drop

hammer here the force for shaping the component is applied in a series of
blows.
Drop forging utilizes a closed impression die to obtain the desire shape of
the component , the shaping is done by the repeated hammering given to the
material in the die cavity. The equipment use for delivering for blows are called
drop hammers. The drop forging die consists of two halves. The lower halve of
the die is fixed to the anvil of the machine , while the upper halve is fixed to
ram. The heated stock is kept in the lower die, while the ram delivers 4-5 blows
ww
on the metal spreads and completely fills in the die cavity. When the two die of
halves closed the complete is formed. The typical products obtained in drop
w .Ea
forging are cranks, crank shaft, connecting rods, wrench, crane hooks etc. The
types of operations are fullering, edging, bending, blocking , finishing and
trimming etc.
sy E
ngi
2. Describe ring rolling and thread rolling process. (April/May 2015)
Ring rolling:
nee
rin
Ring rolling is generally used for producing steel types of railway car
g.n
wheels, rotating rings of jet engines, races of ball bearings, etc. the initial
material for ring rolling is a pierced billet for producing a thick walled ring.
The ring is placed between driving roll and pressure roll as shown in figure.
The driving roll is fixed but it can rotate freely about its axis. The pressure roll
et
applies pressure on the ring towards the driving roll. When the ring is gripped,
it is caused to rotate and at the same time reduced in thickness continuously. In
order to ensure ha a circular ring is rolled, a pair of guide rolls must be used.
59

Thread rolling:
ww
w .Ea
sy E
ngi
nee
rin
Thread rolling is the most economical and fastest method of making
threads. It is actually a cold working process in which a plastic deformation
takes place. No metal is removed and no chips are produced. Cold rolling g.n
strengthens the thread in tension, shear and fatigue. In this process two dies are
used. One of them is stationary and another is reciprocating. The component to
et
be threaded is rolled between these dies. The moving die reciprocates in
reference to the fixed die. The reciprocating die stroke depends on thread
diameter to be produced, as in one stroke the blank makes one complete
revolution.
60

UNIT IV - SHEET METAL PROCESSES

PART-A
1. What is flanging? (May 2015) (Dec 2014)

It is a process of bending edges of sheet metals usually to 90o
2. Define the term formability. (May 2010)
Formability of a material is the ability of the sheet metal to
undergo the desired shape change without failure.
3. What is the spring back effect in sheet metal component?
ww (May 2012) (May 2014)

In bending operation, the bent part retains some of its elasticity
wwhich is recovered after the punch is removed is called spring back.
.Ea
This can be recovered by over bending by an amount that brings the part
sy E
to return to the correct shape.
4. What are the advantages of hydro forming process? (May 2012)
ngi
Thinning of metal, spot stresses and spring back are drastically
reduced or completely eliminated.
• nee
It is used for mass production because work performed per operation
is high.
rin
• Complicated contours can also be made.
g.n
5. Why is it necessary to provide proper clearance between the punch
and die in a shearing operation? (May 2013) et
Clearance is a must to allow fractures to meet when break occurs.
• Clearance is the intentional space between the punch cutting edge
and the die cutting edge.
• Depends on the type of cutting operation, the space between punch
and die is provided known as clearance.
61

6. What is the difference between a cutoff operation and a parting

operation? (May 2014)
Cut-off operation is separating a part from the remaining sheet
without producing any scrap. Parting operation is separating the sheet
into two or more parts.
7. What are the limitations of explosive forming? (Dec 2012)
(i) Highly trained operators are needed.
(ii) Noisy operation.
8. List the advantages of super plastic forming process.(Dec 2013)
ww It is a one step process.

• The process can be used to form complex components in shapes that
w •
are very near the final dimension.
.Ea
Reduction of subsequent machining and Minimizes the amount of
sy E
scrap produced.
9. What is shear angle? Why is it given in punches and dies?
ngi (Dec 2014)
nee
The angle about which the vertical lines tilt is called shear angle. It is
given to reduce the cutting force, shock and to smoothen the cutting operation.
rin
To prevent distortion on the stock material, shear angle will be on the die
member for blanking operation and the shear angle will be on the punch
g.n
member for piercing operation.
10. List out the test methods for testing formability of material. et
(Dec 2015)
a) Formability tests for bulk deformation.
b) Formability test for elastic – plastic deformation.
c) Simulative tests for forming operation.
d) Full scale forming tests.
62

11. Distinguish between piercing and blanking. (Dec 2015)

Piercing: It is the operation of producing the hole on the work piece by
a punch. So it also called as punching operation. The metal removed is
called as scrap, and the metal that is left out is called as work piece.
Blanking: It is the cutting operation of a flat metal sheet. The article
punched out is known as blank. Blank is the required product of the
operation and the metal left behind is considered as a waste.
12. Define peen forming. (May 2010)
Peen forming is a process of well-established surface cleaning. In
ww this process, a stream of metal shots is blasted against the surface of the
blank to be made into required shape.
w
13. How sheet metal operations classified and what are they?
.Ea (May 2015)
sy E
Sheet metal operations are,
• Bending • Forming
• Punching
ngi • Spinning
• Shearing
• Blanking nee • Stamping
• Embossing
rin
14. What is Lancing operation that is done on sheet metals? (Dec 2012)
g.n
It is an operation of cutting on one side and bending on the other side to
form a sort of tab or louver. No metal is removed.
15. Define spring back effect in sheet forming process. et
(Dec 2013) (May 2013)
The increase in included angle of the bent part relative to the included angle
of the forming tool after the tool is removed.
SB = Al – Albt
Albt
Where, SB = spring back
Al = Included angle of the sheet metal part
Albt = Included angle of bending tool
63

PART-B
1. Explain the explosive with neat sketch. (May 2010) (Dec 2012)
(Dec 2013) (Dec 2015) (May-2017)
Explosive forming process:
 Explosive energy used as metal forming
 Sheet-metal blank is clamped over a die
 Assembly is immersed in a tank with water
 Rapid conversion of explosive charge into gas generates a shock wave .the
ww
pressure of this wave is sufficient to form sheet metals.
w .Ea
sy E
ngi
nee
 Operations can be divide into two categories rin
1. Standoff operations
g.n
2. Contact operations
1. Standoff operations
et
 Explosive charge is located at some distance away from the blank and its
energy is transmitted through some fluid medium such as water.
 This technique is used to form blanks into various shapes except welding,
hardening, compacting and cutting process.
2. Contact operations
 This operation mainly used for welding, hardening, compacting and cutting
process.
 The forming of sheet metal is done by generating pressure wave in a fluid.
64

 Explosive charge is directly located over the blank.

 The blank being formed is placed against the female die.
 This female die has required configuration.
 This entire set up of female die and blank is placed inside the work tank.
 The work tank contains water to receive the vibration in the form of
pressure wave.
 The work Tank should be perfectly insulated to avoid heat transfer from the
system to surrounding.
 The explosive charge is ignited by the detonator.
 Due to this, a high-pressure energy is released in the form of waves.
ww  This pressure waves are applied over the blank to obtain the required shape
w of female die.
.Ea
Advantages:
sy E
a) Less capital investment
b) Presses are not required
ngi
c) Only one die is enough to form the sheet metal.
Disadvantages:
nee
a) Highly trained operators are needed.
b) Noisy operation.
rin
Applications:
g.n
This process is mainly used for producing aerospace component.
2. Describe the shearing and bending operations with suitable et
examples. (May 2010) (May 2015 & Dec-2016)
Shearing operations:
Sheet metal subjected to shear stress developed between a punch and a die is
called shearing
Shearing usually starts with formation of cracks on both the top and bottom
edges of the work piece.
These cracks meet each other and separation occurs.Shearing process has three
important basic stages,
65

1. Plastic deformation
2. Fracture and
3. Shear.
The shearing operations are,
i) Blanking ii) Punching iii) Piercing
iv) Power shearing v) Cutting off vi) Parting vii) Notching
viii) Slitting ix) Lancing x) Nibbling xi) Trimming
xii) Shaving xiii) Perforating
The following figures show different types of shearing operations.
ww
w .Ea
sy E
ngi
nee
rin
g.n
et
66

Shearing of sheet metal between two cutting edges:

(1) Just before the punch contacts work;
(2) Punch begins to push into work, causing plastic deformation
ww
Shearing is a process for cutting sheet metal to size out of a larger stock such as roll
stock.
w Shears are used as the preliminary step in preparing stock for stamping
.Ea
processes, or smaller blanks for CNC presses
sy E
 The shearing process produces a shear edge burr, which can be minimized to
less than 10% of the material thickness. The burr is a function of clearance
ngi
between the punch and the die, and the sharpness of the punch and the die.
•
nee
Blanking – Blanking is the operation of cutting a flat shape from the sheet
metal. The portion which is removed is the required part is called as blank and the
operation is called as blanking.
rin
Punching - similar to blanking except cut piece is scrap, called a slug
g.n
et
(a) Blanking and (b) punching.
67

 A slug (the material punched out) is produced in punching operations but not
in piercing work
Piercing is “forming a hole in sheet metal with a pointed punch with no metal fallout
(slug).”
 In this case, a significant burr or deformed sharp edge is created on the bottom
side of the material being pierced.
 Piercing is the operation of cutting internal features (holes or slots) in stock,
without forming slug scrap
Power shearing-this operation is carried out on power shearing machines where
ww the sheet metal is cut between the movable upper cutting blade and fixed lower
cutting blade.
w
Cutting off – in this operation a piece is removed from a strip by cutting along a
.Ea
single line.
sy E
Parting – in parting operation the sheet is sheared into two or more pieces and the
scrap is removed between the two pieces to part them.
ngi
Notching – notching refers to removing pieces of desired shapes from the edge.
nee
Slitting – shearing operations carried out by means of pair of circular blades
called as slitting. It is the operation of marking an unfinished cut through a limited
rin
length only A slit edge normally has a burr, which may be plastically folded over
the sheet surface by rolling the sheet between two rolls.
g.n
Lancing – it is an operation of cutting on one side and bending on the other side
to form a sort of tab (or) louver. In this operation no metal is being removed. et
Nibbling – in a nibbler machine a small straight punch moves up and down
rapidly into a die. A sheet is fed through the gap and many over lapping holes are
made.
Trimming – it is the operation of cutting and removing unwanted excess metal
from the periphery of a previously formed/forged/cast component.
Shaving – the rough edges of a blanked part are removed by cutting thin strip of
metal along the edge on the periphery.
Perforating – this process is used to make multiple holes which are small in
68

diameter and close together, in a flat work material.
Bending Operations:
Straining sheet metal around a straight axis to take a permanent bend
ww
w
Metal on inside of neutral plane is compressed, while metal on outside of neutral plane
is stretched .Ea
sy E
• The material is stressed beyond the yield strength but below the ultimate tensile
strength.
ngi
• The surface area of the material does not change much.
nee
• Bending usually refers to deformation about one axis
V-bending - performed with a V-shaped die
• For low production rin
• Performed on a press brake g.n
• V-dies are simple and inexpensive
et
Edge bending - performed with a wiping die

 For high production
69

 Pressure pad required

 Dies are more complicated and costly
ww
spring back:
wIncrease in included angle of bent part relative to included angle of forming tool
.Ea
after tool is removed
 sy E
Reason for spring back:
When bending pressure is removed, elastic energy remains in bent part,
ngi
causing it to recover partially toward its original shape
nee
rin
g.n
et
 Spring back in bending is seen as a decrease in bend angle and an increase in
bend radius: (1) during bending, the work is forced to take radius Rb and included
angle b' of the bending tool, (2) after punch is removed, the work springs back to
radius R and angle „.
70

3. Briefly explain with a neat sketch hydro forming process.(Dec 2015)

(Dec 2012 & Dec-2016)
 Hydro forming is an effective sheet metal forming process. Hydro

forming can typically obtain deeper draws than conventional deep
drawing operations.
 Hydro forming uses a rigid punch to push a sheet metal work piece into
a rubber membrane. Behind the rubber membrane is a chamber of
pressurized fluid.
 When the work is pressed into the chamber, the rubber membrane
ww surrounds it completely and the pressure of the fluid forces the sheet
wmetal to form on the punch.
.Ea
 Fluid pressure can be controlled during the operation and can be as high
as 15,000 lbs/in2, (100MPa). Due to the large amount of evenly
sy E
distributed pressure on the work piece, very deep draws, (high percent
ngi
reduction), can be performed with hydro forming.
 Friction acts to reduce tensile stresses in the material during the process.
nee
 Lubrication affects friction and is an important factor in any type of
rubber forming, (this includes hydro forming), process.
rin
g.n
 One advantage of manufacturing by a rubber forming process is that the
rubber, or flexible material, will be less likely to damage the surface of
the sheet metal part. et
71

Basic process,
- A metal sheet is placed over a male punch.
- Fluid is on the other side of the metal sheet.
- The punch advances and the metal sheet are forced into the shape of the
punch.
- The hydraulic chamber acts as a mate for the punch.
The basic operation is,
1. The metal is placed between the fluid chamber and the punch bed.
2. The fluid is encased behind a wear pad, and this wear pad is brought into
ww contact with the sheet with pressures up to 5 Kpsi.

3. The punch is advanced with pressures up to 15 Kpsi causing the metal to
wtake the shape of the punch.
.Ea
4. The pressures are released, the punch withdrawn, the fluid chamber
sy E
pulled back to remove the metal part.
ngi
nee
rin
Compared to conventional forming,
- Higher drawing ratios g.n
- Reduced tool costs
- Less scarring of parts
et
- Asymmetrical parts made in on pass
- Many high strength alloys can be formed, for example stainless steel
Methods permissible,
- Punch forming - for large drawing depths
- Negative punch forming - allows recessed features
- Cavity die forming
- Male die forming
- Expansion forming
72

Advantages,
- Any type of sheet material can be used
- Thicknesses of 0.1 to 16mm
- Flexible and easy to operate
- Less expensive tooling
- Reduced setup times
- Reduced die wear
Disadvantages,
- Sharp corners difficult to control
ww- High equipment cost
w
- No holes in surface
.Ea
- Incorrectly set pressures may lead to buckling and tearing for high pressures
Applications,
- Cups/kitchenwaresy E
- Auto body panels
- Covers. ngi
nee
4. What is super plastic forming? Explain with neat sketch. (Dec 2014)
(May 2013) (Dec-2016)
rin
Super plastic forming is a process that is employed to all common metal g.n
working techniques. Following are some of the materials that are being
developed for plastic forming:
et
o Super plastic alloys
o Zinc aluminium (Zn-22AL)
o Titanium-Al(Ti-6AL-V)
o Bismuth-tin
o Aluminium (2004,2419,7475)
o Aluminium – lithium alloys (2090,2091,8090)
73

Super plastic forming process improves productivity by eliminating mechanical

fasteners and it produces parts with good dimensional accuracy and low
residual stress.
The super-plastic forming process is usually carried out at a temperature of

900oC for titanium alloys and at a temperature of 500oC for aluminium alloys.
Operation:
Step 1: The blank is loaded in the form die. The hot press heats the die and the
blank to the material super plastic temperature.
ww
w
Step 2: Once the temperature is attained, the gas pressure slowly inflates the
blank.
.Ea
sy E
ngi
nee
rin
g.n
Step 3: The gas keeps inflating the part to fit the die. The material at the super
plastic temperature can allow up to 5 times elongation.
et
Step 4: At the end of the forming cycles, the part perfectly conforms to the die
even in its smallest details.
74

ww Conventional forming techniques compared to SPF,
w
- require multiple annealing and forming steps
.Ea
- have lower accuracy and repeatability
sy E
- have spring back
- Poorer surface finish
For SPF of aluminum, ngi

- 70-90% of melting temperature nee
- Typical time is 30-120 min.
rin
- Temperature must be carefully maintained
g.n
- Cavitations (voids) can occur in the aluminum if pressure is not applied
to both sides of the sheet - a different pressure still causes motion.
Parts are less expensive because only half of the tooling is required.
et
4. Explain the types of stretch forming operations. (Dec 2014),
(Dec 2015) (May 2013 & May-2017)
 Sheet metal is stretched and simultaneously bent to achieve shape change

 Stretch forming: (1) start of process; (2) form die is pressed into the work with
force Fdie, causing it to be stretched and bent over the form. F = stretching force.
75

 Stretching is the process of stressing the work blank beyond its elastic limit by
moving a form block towards the blank or sheet metal.
 The form block has projection of exact size required on the blank which is in
the form of depression on the same blank.
ww
w .Ea
sy E
Methods of stretch forming
1. Form - block method
2. Mating – die method ngi
nee
rin
g.n
et
Form – block method:

(i) In this method the two end of the blanks or sheet metal is tightly held by an
adjustable gripper.
(ii) This gripper is fixed but adjustable.
(iii) Then the form block is moved towards the blank to make required shape.
76

(iv) The form block is operated by hydraulic cylinder.

Mating – die method:
(i) In this method the blank is held in movable grippers.
(ii) The blank is placed between the lower and the upper die.
(iii) The lower die is kept stationary and upper die is movable one which is
operated by hydraulic cylinder.
(iv) Movable grippers are moved towards the lower die on which only elastic
deformation takes place.
Advantages:
ww Lower strength is required and less tooling costs

Complex shapes with close tolerances can be made
w Weight and material savings
.Ea
Little or no residual stress occurs in the formed parts
Disadvantages:
sy E
Materials must not be super elastic at service temperatures
ngi
Maintenance cost of hydraulic cylinder is high.
neePart - C
1. Describe magnetic pulse forming with neat sketch. (Dec 2014)
rin(May 2013)
Basic operation:
g.n
• A large current discharge is directed through a coil. The coil has been
placed inside another shape. et
• The discharging current creates a magnetic field. In the nearby sheet of
metal an opposing magnetic field is induced. The result is that the two
magnetic fields oppose and a force moves the sheet away from the coil.
• Over a period of time the part is deformed, often to the shape of a
mandrel, or other form.
Applications:
• fittings for ends of tubes
• embossing
77

• forming
• Capacitor banks are used to accumulate charge for larger discharges.
• The part is formed to a mandrel that has a negative image of the part.
• The method generates pressures up to 50 Kpsi creating velocities up to
900 fps, production rates can climb to 3 parts a second.
Generally there are three methods of magnetic forming,
• Swaging
• Expanding
• embossing and blanking
ww Swaging - An external coil forces a metal tube down onto a base shape
(tubular coil).
w
Expanding - an inner tube is expanded outwards to take the shape of an
.Ea
outer collar (tubular coil).
sy E
Embossing and Blanking - A part is forced into a mold or over another
part (a flat coil) - This could be used to apply thin metal sheets to plastic
parts.
ngi
nee
rin
g.n
et
78

UNIT-V - PROCESSING OF PLASTICS
PART A
1. What is film blowing? (May 2010,2012 & Dec 2012)
Blown film extrusion is a technology that is the most common method

to make plastic films, especially for the packaging industry.
The process involves extruding a tube of molten polymer through a die and
inflating to several times its initial diameter to form a thin film bubble.
ww
2. Name two important differences between thermoplastics and
thermosetting plastics. (May 2012)
w
Thermoplastic .Ea
Thermoplastic
materials have
Thermosetting plastic
Thermosetting plastic can withstand
sy E
low melting points; therefore, they can
be remoulded or recycled by exposing
high temperatures without losing its
rigidity. Therefore, thermosetting
it to heat.
ngimaterials cannot be reformed,
remoulded or recycled by applying
nee
heat.
Thermoplastic is synthesized
addition polymerization. rin
by Thermosetting Plastic is synthesized
by condensation polymerization
g.n
3. What is polymerization? (May 2013)
Polymerization is a Chemical reaction in which two or more small,

et
similar molecules are combined to make larger molecules.
4. What is polythene? (May 2011)
Polythene is a tough, light flexible synthetic resin made by polymerizing

ethylene, chiefly used for plastic bags, food containers, and other packaging.
79

5. Define Pulforming. (Dec 2013)
Pulforming is defined as a process that can be used to make parts that

are curved and may have variations in cross section throughout their lengths.
6. What is calendaring in processing of plastics? (May 2011 & May 2013)
Calendaring is a process is used for producing thermoplastic sheets and

films. A plastic compound is made into pliable dough then fed through a series
of graduated, heated rollers. The thickness of the sheet or film is determined
by the spacing between rollers.
ww
7. What are the different types of compression moulds? (Dec 2013)
w
1. Flash type 2.positive type 3.semipositive type
.Ea
8. Name the common thermosetting plastics. (May 2014)
sy E
Polyester, polyurethanes, vulcanized rubber, Bakelite, melamine
ngi
9. Name the adhesives that are used for adhesive bonding of plastics. ( May
2012 &Dec 2014)
Solvent cements, elastomeric

nee cements, monomeric cements,
thermosetting adhesive
rin
10. Define polyaddition. (May 2015)
g.n
Polyaddition is an addition reaction, where many monomers bond
together via rearrangement of bonds without the loss of any atom or molecule. et
11. What are the types of plastics? (May 2016)
Thermo plastic and thermosetting plastic
12. What are the advantages of transfer moulding? (May 2010 & Dec
2011)
1. Higher speed of production
2. Lower maintenance cost
3. More intricate parts with high accuracy can be produced

80

13. Define degree of polymerization. (May 2013 & Dec 2014)
The degree of polymerization usually defined as the ratio of molecular

weight of a polymer and molecular weight of a single monomer.
14. What is compression moulding? (May 2008)
The main objective is to melt the material due to compression.
15. What is parison? (Dec 2009)
Blow moulding consists of extrusion of the heated tabular plastic piece

called as parison which is transferred to the two piece mould.
ww PART B
w
1. What is thermoforming process? Explain with neat sketches. (Nov/Dec
.Ea
2014, April/May 2015 & Dec-2016)
sy E
Thermoforming is a process of shaping flat thermoplastic sheet which
ngi
includes two stages: softening the sheet by heating, followed by forming it in
the mold cavity. Elastomers and Thermosets cannot be formed by the
nee
Thermoforming methods because of their cross-linked structure – they do not
soften when heated.
rin
Thermoplastics which may be processed by the thermoforming method
g.n
are Polypropylene (PP),Polystyrene (PS),Polyvinyl Chloride (PVC),Low
Density Polyethylene (LDPE),High Density Polyethylene (HDPE), Polymethyl
methacrylate (PMMA).
et
Thermoforming is widely used in the food packaging industry for
manufacturing ice cream and margarine tubs, meat trays microwave containers,
snack tubs, sandwich packs, etc.
Thermoforming is also used for manufacturing some pharmaceutical and
electronic articles, small tools, fasteners, toys, boat hulls, blister and skin
packs.
81

There are three thermoforming methods, differing in the technique used

for the forming stage:
1. Vacuum Thermoforming
2. Pressure Thermoforming
3. Mechanical Thermoforming
Vacuum Thermoforming
The process involves shaping a preheated thermoplastic sheet by means
of vacuum produced in the mold cavity space. The atmospheric pressure forces
the soft sheet to deform in conformity with the cavity shape. When the plastic
ww
comes into the contact with the mold surface it cools down and hardens.
w .Ea
sy E
ngi
nee
rin
Pressure Thermoforming g.n
of air pressure. The air pressure forces the soft sheet to deform in conformity
et
with the cavity shape. When the plastic comes into the contact with the mold
surface it
cools
down and
hardens.
82

Mechanical Thermoforming
of a direct mechanical force. A core plug (positive mold) forces the soft sheet
to fill the space between the plug and the negative mold. The process provides
precise dimensional tolerance and surface detailing.
ww
w .Ea
sy E
ngi
nee
2. Explain blow moulding process with neat diagrams? (April/May 2015 &
Dec-2016))
rin
Blow molding is a molding process in which air pressure is used to
g.n
inflate soft plastic into a mold cavity. It is an important industrial process for
making one-piece hollow plastic parts with thin walls, such as bottles and et
similar containers. Since many of these items are used for consumer beverages
for mass markets, production is typically organized for very high quantities.
The technology is borrowed from the glass industry with which plastics
compete in the disposable or recyclable bottle market.
Blow molding is accomplished in two steps: (1) fabrication of a starting

tube of molten plastic, called a parison (same as in glass-blowing); and (2)
inflation of the tube to the desired final shape. Forming the parison is
accomplished by either of two processes: extrusion or injection molding.
83

Extrusion Blow Molding
This form of blow molding consists of the cycle illustrated below. In

most cases, the process is organized as a very high production operation for
making plastic bottles. The sequence is automated and usually integrated with
downstream operations such as bottle filling and labeling. It is usually a
requirement that the blown container be rigid, and rigidity depends on wall
thickness among other factors.
Steps followed in extrusion blow molding are (1) extrusion of parison;
ww
(2) parison is pinches at the top and sealed at the bottom around a metal blow
pin as the two halves of the mold come together; (3) the tube is inflated so that
w
it takes the shape of the mold cavity; and (4) mold is opened to remove the
solidified part. .Ea
sy E
ngi
nee
rin
g.n
et
Injection Blow Molding.
In this process, the starting parison is injection molded rather than

extruded. A simplified sequence is outlined in below. Compared to its
extrusion-based competitor, the injection blow-molding process has a lower
production rate, which explains why it is less widely used.
84

Steps followed in Injection blow molding are (1) parison is injection

molded around a blowing rod; (2) injection mold is opened and parison is
ww
transferred to a blow mold; (3) soft polymer is inflated to conform to a blow
mold; and (4) blow mold is opened and blown product is removed.
w .Ea
In a variation of injection blow molding, called stretch blow molding ,
sy E
the blowing rod extends downward into the injection molded parison during
step 2, thus stretching the soft plastic and creating a more favorable stressing of
ngi
the polymer than conventional injection blow molding or extrusion blow
nee
molding. The resulting structure is more rigid, with higher transparency and
better impact resistance. The most widely used material for stretch blow
molding is polyethylene terephthalate (PET).
rin
g.n
et
Steps followed in Stretch blow molding are (1) injection

molding of the parison; (2) stretching; and (3) blowing.
85

3. Explain Rotational moulding with neat sketches. (May 2012,2013&2017)
Rotational molding uses gravity inside a rotating mold to achieve a

hollow form. Also called rotomoulding, it is an alternative to blow molding for
making large, hollow shapes. It is used principally for thermoplastic polymers,
but applications for thermosets and elastomers are becoming more common.
Rotomoulding tends to favor more complex external geometries, larger parts,
and lower production quantities than blow molding. The process consists of the
following steps: (1) A predetermined amount of polymer powder is loaded into
the cavity of a split mold. (2) The mold is then heated and simultaneously
ww
rotated on two perpendicular axes, so that the powder impinges on all internal
w
surfaces of the mold, gradually forming a fused layer of uniform thickness. (3)
.Ea
While still rotating, the mold is cooled so that the plastic skin solidifies. (4) The
mold is opened, and the part is unloaded. Rotational speeds used in the process
sy E
are relatively slow. It is gravity, not centrifugal force that causes uniform
coating of the mold surfaces.
ngi
nee
Molds in rotational molding are simple and inexpensive compared to
rin
injection molding or blow molding, but the production cycle is much longer,
lasting perhaps ten minutes or more. To balance these advantages and
disadvantages in production, rotational molding is often performed on a g.n
multicavity indexing machine, such as the three-station machine shown below.
The machine is designed so that three molds are indexed in sequence through
et
three workstations. Thus, all three molds are working simultaneously. The first
workstation is an unload-load station where the finished part is unloaded from
the mold, and the powder for the next part is loaded into the cavity. The second
station consists of a heating chamber where hot-air convection heats the mold
while it is simultaneously rotated. Temperatures inside the chamber are around
7000F, depending on the polymer and the item being molded. The third station
cools the mold, using forced cold air or water spray, to cool and solidify the
plastic molding inside.
86

ww
w .Ea
Rotational molding cycle performed on a three-station indexing
sy E
machine: (1) unload-load station; (2) heat and rotate mold; (3) cool the mold.
ngi
A fascinating variety of articles are made by rotational molding. The list
includes hollow toys such as hobby horses, playing balls, boat, sandboxes,
nee
small swimming pools, truck body parts, automotive dashboards, fuel tanks,
rin
furniture, large industrial barrels, containers, and storage tanks. The most
g.n
popular molding material is polyethylene, especially HDPE. Other plastics
include polypropylene, ABS, and high-impact polystyrene.
4. Explain the compression moulding process with neat sketches. (Dec 2012
et
& 2013, Dec-2016 & May-2017)
Compression molding is an old and widely used molding process for

thermosetting plastics. Its applications also include thermoplastic phonograph
records, rubber tires, and various polymer matrix composite parts. The process
consists of (1) loading a precise amount of molding compound, called
the charge, into the bottom half of a heated mold; (2) bringing the mold halves
together to compress the charge, forcing it to flow and conform to the shape of
87

the cavity; (3) heating the charge by means of the hot mold to polymerize and
cure the material into a solidified part; and (4) opening the mold halves and
removing the part from the cavity.
Compression molding for thermoplastics: (1) charge is loaded, (2) and

(3) charge is compressed and cured, and (4) opening the mold halves and
removing the part from the cavity.
ww
w .Ea
sy E
ngi
nee
The initial charge of molding compound can be in any of several forms,
including powders or pellets, liquid, or preform. The amount of polymer must
rin
be precisely controlled to obtain repeatable consistency in the molded product.
g.n
It has become common practice to preheat the charge prior to its placement into
the mold; this softens the polymer and shortens the production cycle time.
Preheating methods include infrared heaters, convection heating in an oven,
and use of a heated rotating screw in a barrel. The latter technique (borrowed
et
from injection molding) is also used to meter the amount of the charge.
Compression molding presses are oriented vertically and contain two

platens to which the mold halves are fastened. The presses involve either of
two types of actuation: (1) upstroke of the bottom platen or (2) downstroke of
the top platen, the former being the more common machine configuration.
They are generally powered by a hydraulic cylinder that can be designed to
provide clamping capacities up to several hundred tons.
88

Molds for compression molding are generally simpler than their

injection mold counterparts. There is no sprue and runner system in a
compression mold, and the process itself is generally limited to simpler part
geometries due to the lower flow capabilities of the starting thermosetting
materials. However, provision must be made for heating the mold, usually
accomplished by electric resistance heating, steam, or hot oil circulation.
Compression molds can be classified as hand molds, used for trial
runs; semiautomatic, in which the press follows a programmed cycle but the
operator manually loads and unloads the press; and automatic, which operate
ww
under a fully automatic press cycle (including automatic loading and
unloading).
w .Ea
Materials for compression molding include phenolics, melamine,
epoxies, urethanes, and elastomers. Typical TS plastic moldings include
sy E
electric plugs, sockets, housings, pot handles, and dinnerware plates.
ngi
Advantages noted for compression molding in these applications include:
molds that are simpler, less expensive, and require low maintenance; less scrap;
nee
and low residual stresses in the molded parts . A typical disadvantage is longer
rin
cycle times and therefore lower production rates than injection molding.
5. Explain the transfer moulding process. (Dec 2012, 2013, 2014 & 2015) g.n
In this process, a thermosetting charge (preform) is loaded into a
chamber immediately ahead of the mold cavity, where it is heated; pressure is
et
then applied to force the softened polymer to flow into the heated mold where
curing occurs. There are two variants of the process: (a) pot transfer molding,
in which the charge is injected from a "pot" through a vertical sprue channel
into the cavity; and (b) plunger transfer molding, in which the charge is
injected by means of a plunger from a heated well through lateral channels into
the mold cavity. In both cases, scrap is produced each cycle in the form of the
leftover material in the base of the well and lateral channels, called the cull. In
89

addition, the sprue in pot transfer is scrap material. Because the polymers are
thermosetting, the scrap cannot be recovered.
Transfer molding is closely related to compression molding, because it

is utilized on the same polymer types (thermosets and elastomers). One can
also see similarities to injection molding, in the way the charge is preheated in
a separate chamber and then injected into the mold. Transfer molding is
capable of molding part shapes that are more intricate than compression
molding but not as intricate as injection molding. Transfer molding also lends
itself to molding with inserts, in which a metal or ceramic insert is placed into
ww
the cavity prior to injection, and the heated plastic bonds to the insert during
w
molding.
.Ea
sy E
ngi
nee
rin
g.n
et
90

(a) Pot transfer molding, and (b) plunger transfer molding. Cycle in both
processes is (1) charge is loaded into pot; (2) softened polymer is pressed into
mold cavity and cured; and (3) part is ejected.
6. Explain the principle of injection moulding process. (Dec 2012 & May
2015, 2016)
Injection molding is a process in which a polymer is heated to a highly

plastic state and forced to flow under high pressure into a mold cavity, where it
solidifies. The molded part, called a molding, is then removed from the cavity.
ww
The process produces discrete components that are almost always net shape.
The production cycle time is typically in the range 10 to 30 seconds, although
w
cycles of one minute or longer are not uncommon. Also, the mold may contain
.Ea
more than one cavity; so that multiple moldings are produced each cycle.
sy E
Complex and intricate shapes are possible with injection molding.
ngi
The challenge in these cases is to design and fabricate a mold whose cavity is
nee
the same geometry as the part and which also allows for part removal. Part size
can range from about 50 g up to about 25 kg, the upper limit represented by
rin
components such as refrigerator doors and automobile bumpers. The mold
g.n
determines the part shape and size and is the special tooling in injection
molding. For large complex parts, the mold can cost hundreds of thousands of
dollars. For small parts, the mold can be built to contain multiple cavities, also
making the mold expensive. Thus, injection molding is economical only for
et
large production quantities.
Injection molding is the most widely used molding process for

thermoplastics. Some thermosets and elastomers are injection molded, with
modifications in equipment and operating parameters to allow for cross-linking
of these materials.
91

Process and Equipment
Equipment for injection molding evolved from metal die casting. An

injection molding machine consists of two principal components: (1) the
plastic injection unit and (2) the mold clamping unit. The injection unit is
much like an extruder. It consists of a barrel that is fed from one end by a
hopper containing a supply of plastic pellets. Inside the barrel is a screw whose
operation surpasses that of an extruder screw in the following respect: in
addition to turning for mixing and heating the polymer, it also acts as a ram
which rapidly moves forward to inject molten plastic into the mold. A
ww
nonreturn valve mounted near the tip of the screw prevents the melt from
w
flowing backward along the screw threads. Later in the molding cycle the ram
.Ea
retracts to its former position. Because of its dual action, it is called a
reciprocating screw, which name also identifies the machine type. Older
sy E
injection molding machines used a simple ram (without screw flights), but the
ngi
superiority of the reciprocating screw design has led to its widespread
adoption in today's molding plants. To summarize, the functions of the
nee
injection unit are to melt and homogenize the polymer, and then inject it into
the mold cavity
rin
g.n
The clamping unit is concerned with the operation of the mold. Its
functions are to (1) hold the two halves of the mold in proper alignment with
each other; (2) keep the mold closed during injection by applying a clamping
et
force sufficient to resist the injection force; and (3) open and close the mold at
the appropriate times in the molding cycle. The clamping unit consists of two
platens, a fixed platen and a movable platen, and a mechanism for translating
the latter. The mechanism is basically a power press that is operated by
hydraulic piston or mechanical toggle devices of various types. Clamping
forces of several thousand tons are available on large machines.
92

ww
w .Ea
The cycle for injection molding of a thermoplastic polymer proceeds in the
sy E
following sequence.
ngi
Let us pick up the action with the mold open and the machine ready to start
a new molding:
nee
(1) Mold is closed and clamped.
rin
(2) A shot of melt, which has been brought to the right temperature and
g.n
viscosity by heating and by the mechanical working of the screw, is injected
under high pressure into the mold cavity. The plastic cools and begins to
solidify when it encounters the cold surface of the mold. Ram pressure is
et
maintained to pack additional melt into the cavity to compensate for
contraction during cooling.
(3) The screw is rotated and retracted with the nonreturn valve open to permit
fresh polymer to flow into the forward portion of the barrel. Meanwhile, the
polymer in the mold has completely solidified.
(4) The mold is opened, and the part is ejected and removed.
93

ww
w
7. Describe film blowing operation. (Dec 2010)
.Ea
to make sy E
Blown film extrusion is a technology that is the most common method
plastic films, especially for the packaging industry.
ngi
The process involves extruding a tube of molten polymer through a die and
nee
inflating to several times its initial diameter to form a thin film bubble.
rin
The majority of polymer films are manufactured by film blowing
g.n
(blown film extrusion). A single screw extruder is used to melt the polymer and
pump it into a tubular die, as shown in cross-section at right. Air is blown into
the center of the extruded tube and causes it to expand in the radial direction.
et
94

Extension of the melt in both the radial and down-stream direction stops at the
freeze line (frost line) due to crystallization of the melt. The nip rolls collect the
film, as well as sealing the top of the bubble to maintain the air pressure inside.
This process is used extensively with polyethylene and polypropylene.
Advantages
 Produce tubing (both flat and gussetted) in a single operation

 Regulation of film width and thichness by control of the volume of air in
the bubble, the output of the extruder and the speed of the haul-off
 Eliminate end effects such as edge bead trim and non uniform
ww temperature that can result from flat die film extrusion
w


Capability of biaxial orientation (allowing uniformity of mechanical
.Ea
properties)
Blown Film Extrusion can be used for the manufacture of co-extruded,
sy E
multi-layer films for high barrier applications such as food packaging.
Applications ngi
nee
Blown film can be used either in tube form (e.g. for plastic bags and
sacks) or the tube can be slit to form a sheet.
rin
g.n
Typical applications include Industry packaging (e.g. shrink film,
stretch film, bag film or container liners), Consumer packaging (e.g. packaging
film for frozen products, shrink film for transport packaging, food wrap film, et
packaging bags, or form, fill and seal packaging film), Laminating film (e.g.
laminating of aluminium or paper used for packaging for example milk or
coffee), Barrier film (e.g. film made of raw materials such as polyamides and
EVOH acting as an aroma or oxygen barrier used for packaging food, e. g. cold
meats and cheese), films for the packaging of medical products, Agricultural film
(e.g. greenhouse film, crop forcing film, silage film, silage stretch film).
95

PART-C
1. Sketch and explain the sequence of steps in manufacturing a connecting
rod using the forging process. (April/May-2017)
 Blank (bar stock)
 Edging
 Blocking
 Finishing
 Trimming
Manufacturing process
1. Material
ww 2. Cutting to length of material

3. Billets heating
w4. Hot forging

5. Piercing
6. Trimming.Ea
8. Machining
sy E
7. Shot blasting /shot peening
 Deburring
 Machining of top surface
 Grinding the side faces ngi
 Drilling the piston end
 Broaching of crank and nee
 Piston rod drilling of bolt hole
 Drilling of hole rin
 Machining of bolt head
 Seat g.n
9. Bush inspection
10. Machine fracture splitting groove
11. Fracture splitting
et
12. Assembly of connecting rod
13. Machining
14. Finish grinding i=of side faces
15. Final drilling of crank and piston
16. Milling of bearing of positioning groove
17. Insertion of crank end bearing shells
18. Insertion of small end bearing
96

Selection of material
The connecting rods are most usually made of steel (for lightness and the
ability to absorb high impact at the expense of durability)
Titanium (for a combination of lightness with strength, at higher cost) for

high performance engines, or of cast iron for applications such as motor
scooters.
Cutting of material • Cut the material a little greater than the required due to
further process
Heating Billets • Billet is heated in the furnace at 500-600 ⁰C
ww
Hot forging • Hot forging is defined as working a metal above its
recrystallization temperature. • The main advantage of hot forging is that as the
w
metal is deformed the strain-hardening effects are negated by the
.Ea
recrystallization process.
Piercing:
Trimming:
sy E
Shot peening: ngi
Machining: nee
Fracture splitting rin
Assembly g.n
Insertion of bearing shell et
Insertion of bering bushes
Inspection
97

2. Explain the design considerations to be followed when designing a part

for the casting process. (April/May-2017)
1. Design the part so that the shape is cast easily.
2. Select a casting process and material suitable for the part, size,
mechanical properties, etc.
3. Locate the parting line of the mold in the part.
4. Locate and design the gates to allow uniform feeding of the mold cavity
with molten metal.
5. Select an appropriate runner geometry for the system.
ww 6. Locate mold features such as sprue, screens and risers, as appropriate.

7. Make sure proper controls and good practices are in place
w Two types of design issues in casting:
.Ea
1. Geometric features and tolerances incorporated into the part
sy E
2. Mould features that are needed to produce the desired casting
Design Issue: Mould Features
1. Partingline
2. Directionalsolidification ngi
nee
3. Pattern withdrawal (Draft/taper allowances)
4. Dimensional tolerance (machining, shrinkage allowances)
5. Surface finish
6. Core design (core elimination) rin
Parting Line
g.n
A part should be oriented in a mould so that the large portion of the casting is
relatively low and the height of the casting is minimized.
In general, the parting line should be along a flat plane rather than be
et
contoured.
The parting line should be placed as low as possible relative to the casting for
less dense metal (such as aluminum alloys) and located at around mid-height
for denser metals (such as steels).
Design Issue: Geometric Features
1. Jointed sections (eliminating hot
spots)
2. Surface integrity
3. Design for functionality and
reduced weight
98

Reg.No.:
Question Paper Code : 72180
B.E./B.Tech. DEGREE EXAMINATION, NOV/DEC 2010.

Third Semester
ww Mechanical Engineering
ME2201-MANUFACTURING TECHNOLOGY-I
w .Ea (Regulation 2008)
Time: Three hours

sy E Answer ALL questions
Maximum: 100 Marks
ngi
PART-A (10X2=20 Marks)
nee
1. List the different types of patterns used in modern foundry. (Pg. No:7)
2. Write a note on chilled casting (Pg. No:8)
rin
3. Differentiate fission welding from fusion welding. (Pg. No:24)
4. Mention the application of friction welding. (Pg. No:26) g.n
5. What is meant by closed die forging? (Pg. No:38)
6. Mention the different types of shape rolling operation. (Pg. No:40)
et
7. Define the term formability. (Pg. No:58)
8. Define peen forming. (Pg. No:60)
9. Write a note on thermoplastics. (Pg. No:78)
10. List the application of transfer moulding . (Pg. No:78)
PART B-(5X16=80 Marks)
11. (a) (i) Explain the properties of moulding sands. (Pg. No:9) (8)
(ii) What is core? Describe the different types of cores used (8)
99

(Or)
(b) (i) Write a note on casting defects, causes and remedies. (Pg. No:21)
(8)
(ii) Describe the procedure of making castings by the investment
casting Process (Pg. No:14) (8)
12.(a) List out the Different types of welding process. Briefly explain the
Working principles of any two welding process (16)
(Or)
(b) What is meant by welding defects? Explain any five welding
ww defects. (Pg. No:36) (16)
w
13.(a) Describe the principle of Hot and Cold working processes.
.Ea
Compare them. (Pg. No:41) (16)
sy E (Or)
with neat Sketches. (Pg. No:43) ngi

(b) Explain the working principle of wire and tube drawing processes
(16)
nee
14 .(a) (i) Write a note on sheet metal characteristics (6)
rin
(ii) Describe the shearing and bending operations with suitable
Examples. (Pg. No:63)
g.n
(Or)
(10)
(b) Explain the explosive and super plastic forming with neat sketches.
et
(Pg. No:61) (16)
15. (a) (i)Explain the application of injection moulding. (Pg. No:90) (8)
(ii) Write down the characteristics of shaping processes for plastics.
(8)
(Or)
(b) Describe the working principles of film blowing and
thermoforming. (Pg. No:93) (16)
100

Reg.No.:
B.E./B.Tech. DEGREE EXAMINAION, MAY/JUNE 2012
Third Semester
Mechanical Engineering
ME 2201/ME 32/PR 1204/MANUFACTURING TECHNOLOGY – I
ww (Regulation 2008)
w
Time : Three hours
.Ea Answer All Questions

Maximum : 100 marks
sy E PART A – (10X2 = 20 marks)
ngi
1. State any four types of pattern. (P. No: 7)
nee
2. What are the causes for the formation of blow holes in the sand casting?
rin
3. What are the functions of flux in welding electrode? (P. No: 23)
4. What are the types of adhesives used in adhesive bonding?
g.n
5. Distinguish between hot working and cold working of metals.(P. No:38)
6. Define extrusion, as manufacturing process. (P. No: 40)
7. What is the spring back effect in sheet metal component? (P. No: 58)
et
8. What are the advantages of hydro forming process? (P. No: 58)
9. Name two adhesives that are used for adhesive bonding of plastics.
10. What is film blowing? (P. No: 77)
PART B – (5X16 = 80 marks)

101

11. a) Figure shows the cross section of a conical component (having a

Flange and axial hole).
Describe briefly, with sketches, the steps involved in making a san

mould to cast this component. Sketch also the shape of the casting as
soon as it is removed from the mould. (16)
ww Or
wb) (i) Explain the various steps involved in Lost wax process with
.Ea
suitable sketches. (P. No: 14) (8)
(ii) Write short notes on the following:
sy E
(1) ceramic mould (P. No: 17) (4)
ngi
(2) centrifugal casting (P. No: 15)
12. a) With the help of suitable diagrams, explain the following types of
(4)
welding: nee
(i) TIG welding process
rin (8)
(ii) Electro slag welding process (P. No: 28)
Or g.n (8)
b) (i) What is the principle of thermit welding? Explain the same with et
a neat sketch of the welding arrangement. (P. No30) (8)
(ii) Explain the principle of operation, advantages and limitations of

electron beam welding. (8)
13. a) (i) With a neat sketch, explain the working of a Pneumatic hammer
for forging. (P. No: 55) (10)
(ii) List four tools used for forging. Sketch any two of them. (6)
Or
102

b) (i) With neat sketches, explain the different types of roll stand
arrangements used in rolling mills. (P. No: 51) (6)
(ii) State clearly for what purpose each arrangement is used. (4)
(iii) With a neat sketch, explain the working principle used in

the drawing process. (6)
14. a) Describe with illustrative sketches, the following sheet metal

operations: (4x4 = 16)
(i) Bending edge of a sheet using wiping-die.
ww (ii) Roll bending
w (iii)Stretch bending
.Ea
(iv) Deep drawing (P. No: 63)
sy E Or
ngi
b) (i) With a neat sketch, explain the rubber pad forming process.
How does it differ from rubber hydro forming process?(P. No:68) (8)
nee
(ii) Dsecribe the metal spinning process with a neat sketch and
state its advantages and specific uses.
rin (8)
g.n
15. a) Illustrate with suitable sketches, the working principles of (i) plunger
type plastic injection moulding machine (ii) screw type plastic injection
moulding machine. (P. No: 90) (16)
et
Or
b) (i) Explain the various steps required to manufacture a plastic

bottle using blow moulding process, with neat sketches. (P. No: 82) (8)
(ii) What is Rotational moulding? Explain the same with

necessary sketch. Mention also its applications. (8)
103

Reg.No.:

B.E./B.Tech. DEGREE EXAMINAION, NOVENBER/DECEMBER 2012
Third Semester
ME 2201/ME 32/PR 1204 – MANUFACTURING TECHNOLOGY – I
ww
Time : Three hours
(Regulation 2008)
Maximum : 100 marks
w .Ea Answer All Questions
sy E PART A – (10X2 = 20 marks)
1. What is meant by core print?

ngi
nee
2. Name the different melting furnaces employed for metal casting.
3. What is meant by carburizing flame in gas welding?
4. What is the principle of Thermit welding?
rin
g.n
5. Working on the metal lead at room temperature, is considered to be hot
working? Why?
6. List two advantages of cold extrusion over hot extrusion.
7. What is Lancing operation that is done on sheet metals?
et
8. What are the limitations of explosive forming?
9. Name two important differences between thermoplastics and
thermosetting plastics.
10. What is film blowing.
PART B – (5X16 = 80 marks)
104

11. a) (i) Describe the various pattern allowances which can be

quantitatively specified. (8)
(ii) What are the desirable properties of moulding sand for sand
casting? Explain briefly each one. (8)
Or
b) (i) With illustrative sketches, explain the various casting defects

indicating, their causes and remedies. (8)
(ii) Explain the stages of preparing shell mould, with suitable

sketches. List the unique advantages of making castings in shell
ww moulds. (8)
w
12. a) (i)
.Ea Discuss the gas welding process and the necessary
equipments needed with suitable sketches. (8)
(ii)
sy EExplain the metal arc welding process with neat sketch. (8)
ngi Or
b) (i)
nee
Explain the plasma arc welding process with a neat sketch
and list out its advantages. (8)
(ii) rin
sketch the different types of weld defects and mention how
they occur.
g.n (8)
13. a) With neat sketches, explain the following smith forging

operations:
et
(i) Upsetting (2)
(ii) Bending (3)
(iii) Swaging (3)
(iv) Fullering (3)
(v) Punching and drifting (3)
(vi) Edging (2)
Or
105

b) With suitable sketches, explain the following:

(i) Stages involved in shape rolling of structural sections. (5)
(ii) Cold extrusion forging. (5)
(iii) Seamless tube drawing. (6)
14. a) Sketch and explain the following sheet metal bearing operations :
(i) Sheet bending using V-die. (4)
(ii) Bending edge of a sheet using wiping-die. (4)
(iii) Roll bending (4)
(iv) Bending a sheet to a round shape using four-slide machine.
ww Or
(4)
w .Ea
b) (i) With a neat diagram, explain the principle of explosive
forming. (8)
sy E
(ii) Explain the hydro forming process with neat sketches. Make
ngi
a brief comparison of this process with conventional deep
drawing.
nee (8)
15.
rin
a) (i) Describe briefly the plunger type injection moulding process
for producing plastic components. (8)
g.n
(ii) Explain, with neat diagrams, the thermoforming process. State its
advantages over other processes.
Or
(8)
et
b) With neat sketches, explain the working principle and applications
of the following moulding processes for plastics:
(i) Compression moulding. (8)
(ii) Transfer moulding. (8)
106

Reg.No.:
B.E./ B.Tech. DEGREE EXAMINATION, MAY/JUNE 2013

Third Semester
ME 2201- MANUFACTURING TECHNOLOGY - I
ww (Regulation 2008/2010)
w
Time: Three hours
.Ea Answer ALL questions

Maximum: 100 marks
sy E PART A - (10 x 2 = 20 marks)
ngi
1. Compare the advantages of metals moulds over sand moulds.
2. What are the functions of flux in melting metals and alloys?
nee
3. What is the minimum distance maintained between two successive spot
welds made by resistance welding? why?
rin
4. Write short notes on transferred and non transferred welding.
5. What is ironing? g.n
6. What is meant by fullering?
7. Define spring back.
et
8. Why is it necessary to provide proper clearance between the punch and die
in a shearing operation.
9. What is polymerization?
10. what is calendaring in processing of plastics?
PART B - (5 X 16 = 80 marks)
11. a).i. what are the allowances given while making pattern? Explain. (8)
107

ii. Describe the process of investment casting. What process controls are
needed in this case? (8)
OR
b). i. Briefly explains the principle, operation, advantages, disadvantages and

application of co2 moulding. (8)
ii. Describe with a neat sketch of cold chamber die casting machine. Give its
advantages and limitations (8)
12. a).i. Explain any four major ways to control the output of arc welding
ww
transformer. (8)
ii. Explain the three variables involved in continuous drive friction
w
welding.
.Ea OR
(8)
one method. sy E
b).i. What are the nondestructive tests used in welding inspection? Explain any
(8)
ngi
ii. Explain with neat sketch the equipment and process of submerged arc
welding.
nee
13. a).i. Briefly explain about seamless rolled ring forging.
(8)
(8)
ii. Briefly explain about flat strip rolling operation.
rin (8)
OR
g.n
b. i. Explain hot working and cold working with advantages and limitations.
ii. Explain with a neat sketch the process of wire drawing.

(8)et
(8)
14. a.i. Explain the basic nomenclature of tube bending with simple sketch.(8)
ii. Discuss super plastic forming with necessary sketches. (8)
OR
b. i. What are the different types of stretch forming? Explain any one. (8)
ii. Explain with a neat sketch the principle and operation of magnetic
pulse forming. (8)
108

15. a. i. What is rotational moulding? State its advantages and limitations. (8)
ii. Explain briefly any two bonding methods of thermo plastics. (8)
OR
b. Explain briefly with neat sketches two commercially used methods of
blow moulding for blowing of plastics bottles and mention their specific
advantages. (16)
ww
w .Ea
sy E
ngi
nee
rin
g.n
et
109

Reg.No.:
B.E./ B.Tech. DEGREE EXAMINATION, NOV/DEC 2013

Third Semester
ME 2201- MANUFACTURING TECHNOLOGY - I
(Regulation 2008/2010)
ww
Time: Three hours Maximum:
Answer ALL questions
100 marks
w .Ea PART A - (10 x 2 = 20 marks)

1. Differentiate shrinkage and porosity.
sy E
2. List the-various sand casting defects.
ngi
3. What is the purpose of flux in welding?
4. Write short notes on Thermit welding.
nee
5. What is the difference between hot and cold working?
6. Differentiate extrusion and forging.
rin
7. Define spring, back effect in sheet forming process.
8. List the advantages of super plastic forming processes. g.n
9. What are the different types of compression moulds?
10. Define pulforming.
et
PART B - (5 X 16 = 80 marks)
11. a.i. Explain any four casting defects and its remedies. (8)
ii.Explain shell moulding with sketches and also list the
advantages over other casting methods. (8)
OR
b.i. Explain .how pipes and cylinder liners are made by
centrifugal, casting process. (8)
ii. Explain lost wax processes with neat sketch. (8)
110

12. a.i. Differentiate electro gas welding and electro slag welding
with its Principles and applications. (8)
ii. Explain gas metal arc welding processes with neat sketch and its
process capabilities. (8)
OR
b.i. Explain the following welding process with neat sketch (16)
(i) Resistance seam welding
( ii) Friction Stir welding.
13. a.i. Explain the steps involved in the forging operation. (8)
ww ii. Explain the precision forging process with neat sketch

and also compare with closed die forging process. (8)
w .Ea
OR
b. i. Explain the various defects present on the rolled plate surfaces
sy E
with suitable sketch.
ii. Write short notes on impact extrusion and hydro static
(8)
extrusion.
ngi (8)
14. a.i. Explain the various
important characteristics. nee
sheet metal forming process with its
(8)
ii. Describe forming limit diagram.
rin (8)
OR
g.n
b. i. Explain the explosive forming process with neat sketch.
ii. How curvatures are made on thin sheet metals, explain the
(8)
et
suitable Process with neat sketch. (8)
15. a. Explain compression moulding and transfer moulding process
with neat sketch. (16)
OR
b. Explain the various moulding process for reinforced plastics. (16)
111

Reg.No.:
B.E/B.Tech DEGREE EXAMINATIONS , MAY / JUNE 2014

Third semester
ME 2201/ME 32 – MANUFATURINGTECHNOLOGY – I
(Regulation 2008/2010)
Time : Three hours Maximum : 100 marks
ww Answer All Questions

PART -A (10×2=20Marks)
w
1. Define casting.
.Ea
2. What is pattern?
sy E
3. What is the difference between soldering and brazing?
4. Sketch different types of oxy acetylene flames.
ngi
5. Define “up setting” and “drawing down” in forging operation.
nee
6. Sketch the different types of rolling mills.
7. What is the difference between a cutoff operation and a parting operation?
8. What is meant springback effect in sheet metal bending?
rin
9. What is polythene?
g.n
10. Name the common thermosetting plastics.
PART -B (5×16 = 80Marks)

et
11. (a) (i) Explain the hot chamber die casting with figure. (8)
(ii) Enumerate some common casting defects and explain the reasons
which cause these defects. (8)
Or
(b) Describe stepwise procedure of making a mould with a two piece
split pattern. (16)
12.(a) Explain the principle of arc welding. What are the different weld
112

positions in arc welding? Enumerate some defects due to arc

welding. (16)
Or
(b) Explain the principle of resistance welding. What are the different types
of resistance welding and explain anyone them with neat sketch. (16)
13.(a) Classify the extrusion process. Explain the backward extrusion and cold
extrusion forging operation. Compare hot and cold extrusion. (16)
Or
ww(b) Explain the mechanism of rolling process with clear sketch. Write about
w
some defects associated with rolling.
.Ea
(16)
sy E
14.(a) An L-shaped part is to be bent in a V- bending operation on a prèss
brake from a flat blank 101.6 mm by 38.1 mm that is 3.96 mm thick. The bend
ngi
of 900 is to be made in the middle of the 101.6 length.
(i) nee
Determine the dimensions of the two equal sides that will
rin
result after the bend, if the bend radius = 4.76 mm. For
convenience, these sides should be measured to the
beginning of the bend radius. g.n (8)
(ii) Also, determine the length of part‟s neutral axis after the
et
bend. (4)
(iii) Should the machine operator set the stop on the press
brake relative to the straight length of the part. (4)
Or
(b) Explain single die and multiple operational die with neat sketch. State
their advantages and limitations. (16)
113

15.(a) (i) Briefly explain the working principle and applications of

injection moulding process with neat sketch. (11)
(ii) The nominal length (L) of a part made of polyethylene is to be 80 mm.

Determine the corresponding dimension of mould cavity (Lc ) that will
compensate for shrinkage (consider the shrinkage of polyethylene S = 0.025).
ww Or
(5)
(b)
w Explain the structure of thermo plastic and thermosetting plastics.
.Ea
Compare the thermo and thermosetting plastics. (16)
sy E
ngi
nee
rin
g.n
et
114

Reg.No.:

B.E/B.Tech DEGREE EXAMINATIONS , NOV /DEC 2014
Third semester
ME 6302 – MANUFATURINGTECHNOLOGY – I
ww
Time : Three hours
(Regulation 2013)
Maximum : 100 marks
w .Ea Answer All Questions
PART -A (10×2=20Marks)
sy E
1. What is meant by grain fineness number?
ngi
2. Mention few applications of centrifugal casting.
nee
3. What is meant by Nugget in Electric Resistance welding?
4. What are the functions of flux used in welding electrodes?
5. Why is drop forging called so?
rin
6. What does angle of bite in rolling mean?
g.n
et
7. What is shear angle? Why is it given punches and dies?
8. What is flanging?
9. What is polymerization?
10. List out any four types of adhesives used in adhesive bonding of plastics.
PART -B (5×16 = 80Marks)
11. (a) (i) Explain various properties required for moulding sand. (8)
(ii) Describe the constructional feature of cupola furnace. (8)
Or
115

11. (b) Explain various steps involved in sand core manufacturing. (16)
12.(a) (i) Explain with neat sketch the components of oxy acteylene gas
welding equipment. (8)
(ii) Describe the process of Electro slag welding and identify their
major applications. (8)
Or
(b) (i) Explain the process of Rotary drive friction welding with its
ww (ii)
advantages and limitations.
Briefly explain the principle of operation, advantages and

(8)
w .Ea
limitations of Electron beam welding. (8)
13.(a) (i)
(ii)
sy E
With suitable sketches describe indirect and direct extrusion. (8)
Draw a simple sketch showing rolling process and make short
ngi
note on deformation of grains in rolling. (8)
Ornee
(b) (i) rin
Explain hot working and cold working with their advantages and
limitations.
g.n (8)
(ii) Explain in detail about wire drawing. (8)

et
14.(a) (i) What is super plastic forming? Explain with a neat sketch. (8)
(ii) Enumerate Rubber Pad forming with suitable sketch. (8)
Or
(b) (i) Enumerate with a neat sketch any two type of stretch forming
operations. (8)
(ii) Describe magnetic pulse forming with a neat sketch. (8)
116

15.(a) (i) What is transfer moulding? Discuss its advantages and

limitations. (8)
(ii) Explain positive, semi positive and flash type compression

moulding. (8)
Or
(b) (i) Explain various types of thermoforming method shaping

thermoplastics. (8)
ww
w .Ea
sy E
ngi
nee
rin
g.n
et
117

Reg.No.:

B.E./B.Tech. DEGREE EXAMINATION, APRIL/MAY 2015.
Third Semester
ME 6302 – MANUFACTURING TECHNOLOGY – I
ww
Time : Three hours
(Regulation 2013)
Maximum : 100 marks
w .Ea Answer ALL questions.
PART A – (10 x 2 =20 marks)

sy E
1. List the different types of patterns.
ngi
2. Write the application of core prints.
nee
3. Name various causes for the defect porosity in the welding.
4. Write the difference between brazing and soldering.
5. What are the various forming processes?
rin
6. Name various defects in parts produced by drawing.
g.n
7. How are sheet metal operations classified and what are they?
8. What is flanging?
9. Define Polyaddition.
et
10. Write short notes on the application of plastics.
PART B – (5x16=80 marks)
11. (a) (i) Explain the properties required for moulding sand. (8)
(ii) Explain the preparation of moulding sand process. (8)
Or
118

(b) (i) Explain any one type of centrifugal casting with neat
diagram. (8)
(ii) Name any five casting defects and explain the remedies
for those defects. (8)
12. (a) (i) Explain various welding positions with neat sketch. (8)
(ii) Explain the submerged arc welding process with neat

diagram. (8)
Or
(b) (i) Explain the arc welding process with neat sketch. (8)
ww (ii) Describe the ultrasonic welding process with neat
w
13. (a) .Ea
(i)
diagram.
Explain hot working and cold working with their

(8)
sy E advantages and limitations. (8)

(ii)
ngi
Explain various forging operations.
Or
(8)
(b) (i) nee

Describe the ring rolling and thread rolling process. (8)
(ii)
rin
Explain the forward and backward extrusion process. (8)
14. (a) (i) Explain the various properties of sheet metal. g.n (8)
(ii) Describe the nibbling and notching operations.
Or
(8)et
(b) (i) Explain the different types of bending process. (8)
(ii) In detail explain the Coining and Embossing Process. (8)
15. (a) (i) Write the difference between thermoplastics and
thermosetting plastics. (8)
(ii) Explain the injection blow moulding process. (8)
Or
(b) (i) Explain the calandring process. (8)
(ii) Describe any two types of thermoforming process. (8)
119

Reg.No.:

B.E./B.Tech. DEGREE EXAMINATION, NOV/DEC 2015.
Third Semester
ME 6302 – MANUFACTURING TECHNOLOGY – I
ww (Regulation 2013)
w
Time : Three hours
.Ea Answer ALL questions.

Maximum : 100 marks
sy E PART A – (10 x 2 =20 marks)
ngi
1. What is the ideal profile of a sprue?
2. What do you meant by core print?
nee
3. Why shielding of weld area during welding is required?
rin
4. How does the seam welding is an application of spot welding?
5. What do you meant by Lateral Extrusion?
g.n
6. What do you meant by angle of bite?
7. List out test methods for testing formability of material. et
8. Distinguish between piercing and blanking.
9. What is the need for Rotational moulding in manufacturing plastic
components?
10. Make a note on Polymerization.
PART B – (5x16=80 marks)
11. (a) (i) Explain operation of cupola furnace with necessary sketch.
(8)
120

(ii) Explain any four casting defects, causes and remedies.

(8)
Or
(c) (i) Explain the various types of pattern used in Mould

making. (8)
(ii) Enumerate the steps in sequence for producing Shell
Moulding. (8)
12. (a) (i) Explain the equipment of an Oxy-Acetylene gas welding.
(8)
ww (ii) Explain about the equipment and operation of GTAW
w .Ea process. (8)
(b) (i)
sy E Or
Explain the variants of Thermit welding process. (8)
(ii) ngi
Explain the Resistance spot welding process with a neat
sketch nee (8)
13. (a) (i) rin

Explain with neat sketches various types of rolling stand
arrangement.
g.n (8)
(ii) Explain with a neat sketch the process of wire drawing. (8)
Or et
(b) (i) Discuss the advantages and limitations of hot working and
cold working (8)
(ii) Explain the steps involved in drop forging with neat
sketches. (8)
14. (a) (i) Explain any one stretch forming method. (8)
(iii) Explain the advantages and limitations of compound dies
over progressive dies. (8)
121

Or
(b) (i) Briefly explain with a neat sketch hydroforming. (8)
(ii) Elucidate process variables in Explosive forming. (8)
15. (a) (i) Explain how plastic sheets are manufactured by thermo
forming method. (8)
(ii) Explain the process of transfer moulding and its
applications. (8)
Or
ww (b) (i)
(ii)
Enumerate various methods of bonding thermoplastics. (8)
Enumerate injection moulding of plastic products. (8)
w .Ea
sy E
ngi
nee
rin
g.n
et
122

Reg.No.:
B.E/B.Tech. DEGREE EXAMINATION, MAY/JUNE 2016

Third semester
ME 6302-MANUFACTURING TECHNOLOGY-I
(Regulation 2013)
Answer ALL Questions.
ww
Time: Three Hours
PART-A (10 x 2 = 20 Marks)
Maximum: 100 Marks
w .Ea
1. What are the causes of “misruns” in castings?
sy E
2. What are chaplets? (P. No: 9)
3. Why is spot welding commonly used in automotive bodies and in large
appliances?
ngi
nee
4. What is the role of flux in welding operation? (P. No: 23)
5. Why is the surface finish of a rolled product better better in cold rolling
than in hot rolling? (P. No: 41)
rin
6. What is strain rate sensitivity?
g.n
7. Estimate the force required for punching a 25mm diameter hole through
a 3.2mm thick annealed titanium alloy Ti-6Al-4V sheet at room
temperature. The UTS for this alloy can be assumed to be 1000Mpa.
et
8. Name any two super plastic materials.
9. Viscosity is an important property of a polymer melt in plastics shaping
processes, upon what parameters does viscosity depend?
10. What is the difference between a positive mould and a negative mould
in thermoforming?
PART-B (15 x 16 = 80 Marks)
11. (a) (i) why are steels more difficult to cast than cast irons?
123

(ii) What are the operations required in sand casting after the casting
is removed from the mould? Write briefly about any of them.
OR
(b) (i) what is the drawback of hot-chamber die casting with respect to
casting of different metals?
(ii) With neat diagrams explain the process of cold-chamber die

casting operation.
12. (a) (i) what are the advantages and disadvantages of welding compared
ww to other types of the assembly operations?

(ii) What is the principle of resistance welding process? (P. No: 31)
w .Ea OR
13.
(b)
sy E
Explain gas metal arc welding process with a neat diagram.
(a) With neat diagram explain the process of forward extrusion. Explain
ngi
also how hollow sections can be produced in this process. (P. No: 49)
OR nee
rin
(b) A 300mm wide strip 25mm thick is fed through a rolling mill with
two powered rolls each of radius =250mm. the work thickness is to be
g.n
reduced to 22mm in one pass at a roll speed of 50rev/min. the work
material has a flow curve defined by K=275Mpa and n=0.15. Determine et
if the friction between the rools and the work is assumed to be 0.12.
Determine if the friction is sufficient to permit the rolling operation to
be accomplished. If so, calculate the roll force, torque and horse power.
14. (a) Write short notes on the following:
(i) Shearing
(ii) Blanking
124

(iii) Clearance in shearing
(iv) Springback in bending (P. No: 63)
OR
(b) With a neat diagrams explain the process of Rubber pad forming and
Hydroforming. (P. No: 69)
15. (a) (i) Briefly describe the injection moulding process. (P. No: 90)
(ii) Discuss any two of the defects that occur in plastic injection
ww moulding. (P. No: 90)
w .Ea
OR
(b) Explain the process of compression moulding with neat diagrams.

(P. No: 86)sy E
ngi
nee
rin
g.n
et
125

Reg.No.:
B.E/B.Tech. DEGREE EXAMINATION, Nov/Dec- 2016

Third semester
(Regulation 2013)
ww
Time: Three Hours
PART-A (10 x 2 = 20 Marks)
Maximum: 100 Marks
w .Ea
1. What are the characteristics of core?
sy E
2. Name the alloys which are generally die cast. Why are aluminium alloys
preferably cast in cold chamber die casting
ngi
3. Why do residual stresses get developed in weldments?
nee
4. Why the temperature in plasma arc welding is much higher than in other
arc welding processes?
5.
rin
Why is it necessary to condition the metal before hot rolling
6. Give a few examples for hot forged products?
7. What are the desirable qualities in metal for maximum strechability?g.n
8. What are applications of rubber pad forming?
9. Name the various methods of processing thermoplastics.
et
10. Define film blowing?
PART-B (5 x 13 = 65 Marks)
11. (a) (i) How are patterns classified? Describe any two types with
sketches and state the uses of each of them. (7)
(ii) Enumerate the casting defects and suggest suitable remedies. (6)
Or
(b) (i) Explain the processes of centrifugal casting with suitable sketch and
state its specific applications (8)
126

(ii) What are the main characteristics of a mould sand? (5)

12.(a) (i) compare MIG and TIG welding in respect of their principle of
working and field of application. (8)
(ii) What is a soldering flux? What different types of soldering fluxes are used?
(5)
Or
(b) Write short notes on (i) Electron beam welding (ii) Friction stir welding
(6+7)
13. (a) (i) Briefly explain the various operations performance in forging
ww
process. (7)
(ii) With suitable sketches, explain the stages involved in shape rolling of
w
structural sections. (6)
.Ea Or
sy E
(b) (i) Explain the working of Mannesmann process with nest sketch (7)
(ii) How is tube drawing carried out ? Explain with suitable sketch (6)
ngi
14. (a) (i) Explain the various sheet metal forming operations with neat
sketches. (8)
nee
(ii) Discuss with neat sketch, the working of metal spinning processes (5)
Or
rin
(b) With neat sketches explain the following (i)Hydro forming and (ii) super
g.n
plastic forming (6+7)
15. (a) Describe the following plastic processing methods with neat sketches et
(i) Compression moulding (ii) Blow moulding (7+6)
Or
(b) (i) Why is the thermoforming a valuable method for the plastic
Manufacturer? Explain the process with neat sketch. (7)
(ii) State the purpose of the following in plastic (1) Plasticizers
(2) Fillers and (3) Stabilizer. (6)
127

PARTC-(1X15=15 Marks)
16. (a) Derive the mathematical expression for the flat strip metal rolling
Process to calculate the rolling load (15)
Or
(b) A casting is required to have the following composition:C-3.25%,Si-
1.8%,Mn-0.6%, P-0.5% and S-0.1%. Determine the weight of pig iron from
pile A and pile B to be picked up in each metal charge if the charge (200 kg) is
to contain pig iron -50%, foundry return -40%and purchased scrap -10%,
Analysis of these metals is as follows: (15)
ww Metal Si% Mn% S% P%
w
Pigiron (pile A) 2.4 0.9 0.05 0.4
.Ea
Pigiron (pile B) 1.4 0.95 0.05 0.35
sy E
Foundary returns 1.7 0.6 0.06 0.3
Purchased scrap
ngi2.2 0.7 0.07 0.25
nee
rin
g.n
et
128

Reg.No.:
B.E/B.Tech. DEGREE EXAMINATION, April /May - 2017

Third semester
(Regulation 2013)
ww
Time: Three Hours
PART-A (10 x 2 = 20 Mark
Maximum: 100 Marks
w
1. What is meant by permanent mould casting?
.Ea
2. What is the cause of the casting defect called “Hot tear”?
sy E
3. Sketch an oxidizing flame in Oxy acetylene gas welding.
4. What are the two types of plasma arc welding?
ngi
5.How can reduce the “roll force” in a rolling process?
nee
6. Differentiate between hot and cold forging?
7. What are the two most common shearing operations?
8. What is meant by spring back in sheet metal work? rin
9. Define Thermo forming process? g.n
10. Mention any two applications of Blow moulding process?
PART B- (5X13=65 Marks)
et
11. (a) With neat sketches, explain the sand casting process. (13)
Or
(b) With a neat sketch, explain the principle of the Investment casting
Process. (13)
12. (a) Explain the principle and equipment of Gas tungsten arc welding
process with neat sketches. (13)
Or
129

(b) (i) Sketch and name the various componentsof the Thermit welding
process. (8)
(b) (ii) Explain any two important defects in welding process. (8)
13.(a) Sketch and explain the various types of Rolling mill arrangements used
in a Rolling process. (13)
Or
(b) ) Sketch and explain the difference between impression die forging and
precision forging (near net shape forging) operation. (13)
Or
ww
14. (a) With neat sketches explain the Sequence of the Stretch forming process.
(13)
w .Ea
Or
(b) With a neat sketch explain the Explosive forming process. (13)
sy E
15. (a) Explain the Rotational molding process used in manufacturing plastics,
with a neat sketch. (13)
ngi
Or
nee
(b) Explain the Compression molding process with a neat sketch.
(13)
PART C- (1X15=15 Marks)
rin
g.n
16. (a) Explain the design considerations to be followed when designing a part
for the casting process.
Or et
(b) Sketch and explain the sequence of steps in manufacturing a connecting
rod using the forging process.
130

ww
w.E
a syE
ngi
nee
rin
g.n
et
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S.NO TOPIC PAGE NO.

.Ea UNIT III ADVANCES IN METROLOGY

13 Part - A (2 Marks Q &A) nee 61

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25 Nov/Dec 2014 115

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ME6302 MANUFACTURING TECHNOLOGY –I LTPC

impression and closed die forging – forging operations. Rolling of metals–

UNIT IV SHEET METAL PROCESSES ngi

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 To introduce the concepts of basic manufacturing processes and

 To understand the basic fundamentals of manufacturing process

 To learn practical knowledge about foundry & welding area

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Industry / Practical connectivity of the subject:

1. Balaji foundary services- copper based alloys LTB Phosper bronze

Address: No114, athipalayam road, Ganapathy Kottaram,Coimbatore-641006

Address:No-6 senalipalayam Nggo colony, Thydiyalur Coimbatore-641022

DEPARTMENT OF MECHANICAL ENGINEERING

TEXT BOOKS: .Ea

2. Roy. A. Lindberg, "Processes and Materials of Manufacture", PHI / Pearson

5. Rao, P.N. "Manufacturing Technology Foundry, Forming and Welding",

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4 Moulding sand Properties and testing 2 7 T1, R1

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and closed die forging- Characteristics

33 ww Formability of sheet metal - Test

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UNIT I- METAL CASTING PROCESS

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8. What is core print? Mention its purpose. (Nov/Dec-2012) &

ww 1. Cupola Furnace: For cast iron.

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 Die casting is economically benefiting for high productive

ww (May/June-2012) & (May/June-2016)

 Not adequately vented mould

 Rusted damp chills, chaplets and inserts

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 the amount of distortion allowances varies from 2mm to 20 mm as per

mold, which exactly matches nee

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 Formation of hollow interiors in cylinders without cores

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 More segregation of alloy component during pouring under the forces of

5. Explain in detail the working principle Shell moulding process, product

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ww  The process generates noxious fumes which must be removed.

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The main considerations in selection of cupolas are melting capacity,

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 The charge consists of alternate layers of the metal to be melted, coke

 The fuel is burnt in air which is introduced through tubers positioned

Working of Cupola Furnace

ww in alternating layers through an opening in the cylinder.

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