INDIAN INSTITUTE OF TECHNOLOGY PATNA

DEPARTMENT OF MECAHNICAL ENGINEERING

TYPE A, B.TECH END SEMESTER –V, DATE: 26-11-2021
MANUFACTURING TECHNOLOGY – I (ME 331)

Time duration: 30 minutes from the email time + 5 minutes time for sending your file to
me331batch2021@gmail.com

Max. Marks: 50
Note: 1. Questions are having 1 mark.
2. 0.50 negative marking.
3. Make the answer bold highlighted in red color.
4. Convert into pdf and sent to me331batch2021@gmail.com; within the 5 minutes time limit.
5. Save your pdf file using your roll number

1. Match and answer

Welding process Heat source
(a) Thermit welding Chemical reaction
(b) Seam welding Exothermic chemical reaction
(c) MIG welding Electric spark
(d) Friction welding Ohmic resistance
Mechanical work
Electric arc

(a) a−2,b−4,d−6,c−5, (b) a−2,b−4,c−6,d−5, (c) a−2,c−4,b−6,d−5, (d) b−2,a−4,c−6,d−5, (e)

d−2,b−4,c−6,a−5, (f) none

2. Penetration in an arc welding is increased by

(a) increasing welding current and welding speed, (b) increasing welding current and decreasing
welding speed, (c) decreasing welding current and welding speed, (d) increasing welding current and
increasing welding speed, (e) increasing current only, (f) None

3. At small variations of arc length at operating conditions, the manual metal arc welding transformer
provides nearly
(a) Constant power, (b) Constant current, (c) Constant voltage, (d) Constant power factor, (e) Voltage
and current both,(f) None

4. For resistance spot welding of 1.5 mm thick steel sheets, the current required is of the order
(a) 10 amp, (b) 100 amp, (c) 1000 amp, (d) 10,000 amp, (e) 500, (f) 5000

5. Stick (Arc) welding uses a coated electrode, what is the purpose of this coating?
(a) The coating insulates the welder from electric shocks, (b) The coating helps clean the weld zone
from contaminates such as rust or paint, (c) The coating prevents water from damaging the
electrode, (d) The coating produces a protective gas to prevent porosity, (e) Controls the current, (f)
controls the voltage

6. Why shouldn't you wear nylon clothing when welding?

(a) Because you will get too sweaty, (b) It is fine to wear, (c) Because static electricity can build up
cause shocks, (d) Because it can catch fire easily and melt to your skin, (e) Because it absorbs sweat,
(f) None
7. In Ultrasonic welding, which is incorrect
(a) Solid state joining, (b) works on vibration, (c) uses connective bolts, (d) a and b, (e) b and c, (f) a
and c

8. Friction welding produces welds due to ______

(a) electrode melting
(b) workpiece melting
(c) relative motion between workpieces
(d) adhesive force between workpiece particles
(e) Due to current passing through
(f) Electrode and workpiece melting

9. Which of the following is true about friction welding?

(a) One workpiece is held stationary while the other is moving
(b) Both the workpieces are moving
(c) Both the workpieces are stationary and filler is added in the space between them
(d) The material is deformed elastically
(e) Material is melted
(f) Electrode melts between workpieces

10. Which of the following is not true about friction welding?

(a) Oxides can be removed after the welding process
(b) Automation is possible
(c) Rapid welds are made
(d) Process can be used for limited materials
(e) The process can be easily automated for mass production
(f)  The process is comparatively very efficient a rapid

11. Heat input in arc welding depends on

(a) Current only, (b) Voltage only, (c) Electrode resistance only, (d) electrode velocity
(e) a and b, (f) All

12. Heat input during arc welding is 500 watts, if current is 5 Amp, then find the potential difference
(a) 150, (b) 75, (c) 120, (d) 20, (e) 40, (f) None

13. The relation between arc length (l) and voltage (V) with constants a and b is
(a) V= l+a*b, (b) V= I 2+a/b, (c) V= l/(a+b), (d) V*I= a*b, (e) V= a+ b*l, (f) None

14. If heat input efficiency is 80% in an arc welding, then calculate heat supplied by the machine at 10
Amp current and 50 V for 10 seconds,
(a) 400, (b) 500, (c) 600, (d) 300, (e) 200, (f) None

15. The power supplied in arc welding is 1000 Watts at a current of 25 Amp. If the voltage (V) and arc
length (l) characteristics is V = 20 + 2l. Find the arc length (mm)
(a) 5, (b) 10, (c) 20, (d) 50, (e) 100, (f) None

16. At current of 50 Amp and voltage of 80, the net heat input for 5 seconds is 16000 joules. Then
find the system efficiency
(a) 75%, (b) 60%, (c) 90%, (d)70%, (e) 50%, (f) None
17. Voltage-Ampere characteristics of power in arc welding is (Here OC is open circuit and SC is
short circuit)
(a) V/Voc+I/Isc =1, (b) V/I+Voc/Isc=1, (c) V*I/(Voc*Isc)=1, (d) (V+I)/(Voc+Isc)=1, (e)
V*Isc/(Voc*I)=1, (f) None

18. Match the following metal forming processes with their associated stresses in the Work-piece….

Metal forming process Type of stress

1. Coining P. Tensile stress
2. Wire drawing Q. Shear
3. Blanking R. Tensile and compressive
4. Deep drawing S. Compressive
(a) 1-S, 2-P, 3-Q, 4-R
(b) 1-P, 2-Q, 3-S, 4-R
(c) 1-S, 2-P, 3-Q, 4-R
(d) 1-P, 2-R, 3-S, 4-Q
(e) 1-R, 2-S, 3-Q, 4-P
(f) 1-R, 2-P, 3-S, 4-Q

19. The shear strength of sheet metal is 300 MPa. The blanking force required to produce a blank
of 100 mm diameter from a 1.54 mm thick sheet is close to
(a) 45kN
(b) 70 kN
(c) 141 kN
(d) 3500 kN
(e) 70000 kN
(f) None of above

20. In a deep drawing of sheets, the values of the limiting draw ratio depend on
(a) Percentage of elongation of the sheet
(b) Yield strength of materials
(c) Shear strength of materials
(d) Type of press used
(e) Thickness of sheet
(f) The bulk modulus of materials

21. Which of the following manufacturing processes operates under the influence of external forces
(a) Metal forming , (b) Powder metallurgy, (c) casting, (d) deep drawing
(e) welding, (f) none of above

22. Which of the following processes is not the type of bulk-forming process in the metal forming
(a) Bending, (b) Rolling, (c) Forging, (d) Extrusion, (e) Deep drawing, (f) None of above

23. Which of the following manufacturing processes is mainly considered for producing the
components of very high strength
(a) Casting, (b) Forging, (c) Extrusion, (d) Rolling, (e) Sheet metal forming, (f) None of above

24. Which of the following metal forming processes is best suitable for making the wire
(a) Forging, (b) Extrusion, (c) Drawing, (d) Rolling, (e) Metal forming, (f) None of above
25. Calculate the punch size in mm, for a circular blanking operation for which details are given
below.
Size of the blank 25 mm
Thickness of the sheet 2 mm
Radial clearance between punch and
0.06 mm
die
1.05 m
Die allowance
m

(a) 24.83, (b) 24.89, (c) 25.01, (d) 25.17, (e) 25.20, (f) 24.93

26. A 10 mm deep cylindrical cup with a diameter of 15 mm is drawn from a circular blank.
Neglecting the variation in the sheet thickness, the diameter (up to 2 decimal points accuracy) of the
blank is _________ mm.
(a)26, (b) 28.60, (c)29.72, (d) 30, (e) 27, (f) 28.72

27. A shell of 100 mm diameter and 100 mm height with a corner radius of 0.4 mm is to be produced
by cup drawing. The required blank diameter is
(a) 312 mm, (b)230 mm, (c)224 mm, (d)175 mm, (e)161 mm, (f) 151 mm

28. The process of hot extrusion is used to produce

(a) Large size pipes used in city water mains
(b) Stainless steel tubes used in furniture
(c) Curtain rods made of aluminum
(d) Ic engine cylinder
(e) Steel pipe of domestic water supply
(f) None of above

29. In a rolling process, the state of stress of the material undergoing deformation is
(a) Pure compression, (b) Shear, (c) Compression and shear, (d) Pure tension
(e) Tension and shear, (f) None of above

30. Which of the following components is mainly manufactured by performing metal forging
(a) Piston, (b) Engine block, (c) Connecting rod, (d) Crankcase, (e) Cylinder,
(f) None of above

31. What is the shape of the billet used in the extrusion process
(a) Cylindrical, (b) Spherical, (c) Pyramidal, (d) Cubical
(e) Cuboid, (f) None of above

32. Up to what size can wire can be drawn by a wire drawing process
(a) 0.01 mm, (b) 0.02 mm, (c) 0.03 mm, (d) 0.04 mm, (e) 0.05 mm, (f) 0.06 mm

33. Which of the following metal is used in the wire drawing process in die making
(a) Iron, (b) Copper, (c) Magnesium, (d) Aluminum, (e)Tungsten, (f) Lead

34. For sand-casting a steel rectangular plate with dimensions 80 mm × 120 mm × 20 mm, a
cylindrical riser has to be designed. The height of the riser is equal to its diameter. The total
solidification time for the casting is 2 minutes. In Chvorinov’s law for the estimation of the total
solidification time, exponent is to be taken as 2. For a solidification time of 3 minutes in the riser, the
diameter (in mm) of the riser is……51.87mm………
35. Match the casting defects (Group A) with the probable causes (Group B)
Group A Group B
P: Hot tears 1: Improper fusion of two streams of liquid metal
Q: Shrinkage 2: Low permeability of the sand mould
R: Blow holes3: Volumetric contraction both in liquid and solid stage
S: Cold Shut 4: Differential cooling rate
(a) P-1, Q-3, R-2, S-4, (b) P-4, Q-3, R-2, S-1, (c) P-3, Q-4, R-2, S-1
(d) P-1, Q-2, R-4, S-3, (e) P-2, Q-1, R-4, S-3, (f) P-2, Q-4, R-1, S-3

36. The hot tearing in a metal casting is due to

(a) high fluidity, (b) high melt temperature, (c) wide range of solidification temperature, (d) low
coefficient of thermal expansion, (e) Low permeability, (f)High thermal expansion coefficient

37. Two streams of liquid metal which are not hot enough to fuse properly result into a casting defect
known as:
(a) cold shut, (b) swell, (c) sand wash, (d) scab, (e) misrun, (f) Pin hole

38. While cooling, a cubical casting of side 40 mm undergoes 3%, 4% and 5% volume shrinkage
during the liquid state, phase transition and solid state, respectively. The volume of metal
compensated from the riser is
(a) 2%, (b) 7%, (c) 8%, (d) 9%, (e) 5%, (f) 10%

39. Volume of a cube of side ‘l’ and volume of a sphere of radius ‘r’ are equal. Both the cube and the
sphere are solid and of same material. They are being cast. The ratio of the solidification time of the
cube to the same of the sphere is
4π 3 𝑟 6 4π 4 𝑟 6 4π 2 𝑟 6 4π 2 𝑟 4 4π 6 𝑟 4
(𝑎) ( ) ( ) , (𝑏)( ) ( ) , (𝑐)( ) ( ) , (𝑑)( ) ( ) , (𝑒)( ) ( )
6 𝑙 6 𝑙 6 𝑙 6 𝑙 6 𝑙

4π 5 𝑟 3
(𝑓)( )( )
6 𝑙

40. In a Gating system, the ratio 1:2:4 represents:

(A) casting area: ingate area: sprue base area
(B) pouring basin area: ingate area: runner area
(C) sprue base area: ingate area: casting area
(D) runner area: ingate area: casting area
(E) ingate area: runner area: casting area
(F) sprue base area: runner area: ingate area

41. Match the items in Column I and Column II

Column I
P.  Metallic Chills
Q. Metallic Chaplets
R. Riser
S. Exothermic Padding
Column II
1.  Support for the core
2.  Reservoir of the molten metal
3.  Control cooling of critical sections
4.  Progressive solidification

(a) P-1, Q-3, R-2, S-4, (b) P-1, Q-4, R-2, S-3, (c) P-3, Q-4, R-2, S-1, (d) P-4, Q-1, R-2, S-3, (e) P-2,
Q-1, R-4, S-3, (f) P-2, Q-3, R-1, S-4
42. In sand casting fluidity of the molten metal increases with
(A) Increase in degree of super heat
(B) Decrease in pouring time
(C) Increase in thermal conductivity of the mold
(D) Increase in sand grain size
(E) Increase the permeability
(F) Increase in of moisture content beyond 6 percent

43. Which of the following casting processes uses expandable pattern and expandable mold?
(A) Shell mold casting
(B) Investment casting
(C) Pressure die casting
(D) Centrifugal casting
(E) Gravity die casting
(F) Vacuum die casting

44. Chills are used in casting molds to-

(A) To obtain a good quality of product
(B) Reduce the roughness of top surface of the cast product
(C) Increase the solidification time
(D) Reserve excess metal
(E) Increase the productivity
(F) Achieve directional solidification

45. Match the items in the first column to their functions in the second column:

(A) P-1, Q-2, R-3, S-4

(B) P-2, Q-4, R-1, S-3
(C) P-4, Q-2, R-1, S-3
(D) P-2, Q-4, R-3, S-1
(E) P-3, Q-1, R-4, S-2
(F) P-4, Q-1, R-3, S-2

46. In a metal casting process, molten copper alloy is poured into a sand mould. The level of molten
metal in the pouring basin is at a height of 300 mm from the runner having diameter of 10 mm. If the
𝑘𝑔
density and melting temperature of molten copper alloy are 9000  3 and 1000 degC, respectively
𝑚
3
𝑐𝑚
then the rate of flow of molten metal into the mould neglecting friction and other losses, in  𝑠
is
…………………

47. Which of the following process would produce strongest components?

(a) die casting, (b) hot rolling , (c) cold rolling, (d) Investment casting, (e) Forging, (f) Sand casting

48. Hardness of green sand mould increases with

(a) Increase in of moisture content beyond 6 percent
(b) Increase in permeability
(c) Increase in thermal conductivity of the mold
(d) Increase in both moisture content and permeability
(e) Decrease in permeability
(f) None of the above

49. In a sand casting of a rectangular slab, the thickness of the solidified layer after 2 minutes is
known to be 3 cm. Based on Chvorinov’s rule, the solidified thickness after 4 minutes is
(a) 3.15 cm, (b) 3.64 cm, (c) 4.24 cm , (d) 4.95 cm, (e) 2.95cm, (f) 4.55 cm

50. Which of the following materials can be used for making pattern?
1.Aluminium 2. Wax 3. Mercury 4. Lead 5. Wood
Select the correct answer using the codes given below: Codes:
(a) 1, 3 and 4
(b) 2, 3 and 4
(c) 1, 2 and 4
(d) 2, 3 and 5
(e) 2, 1 and 5
(f) 1, 2 and 3