MANUFACTURING PROCESS

Ref. No.: Ex/ME/T//2021

B.E. MECHANICAL ENGINEERING 2nd YEAR 2nd SEMESTER EXAM 2021

MANUFACTURING PROCESS

Time: hours Full Marks: 70

Instructions:

READ THE INSTRUCTION CAREFULLY

A. Write your Name and Full Roll No. clearly at the top of answer script.
B. Answer of part of a question should be written in one place.
C. Send the answer script via email: sumannihar.mech@jadavpuruniversity.in
D. Write your full name, roll no in bracket in the subject of the mail.
Email SUBJECT: NAME (ROLL NO)
E. You may contact at 98300 90204 (call/ text message/ whatsapp message) if any problem
arise during exam.
F. Answer script will be in PDF format.
DON’T FOLLOW ANY UNFAIR MEANS IN THE EXAMINATION.
WRITE ANSWER IN YOUR LANGUAGE FROM OWN UNDERSTANDING

Question No.: 1 & 2 compulsory

Answer of parts of a question should be written in one place.

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1. Fill in the blanks, write true or false & multiple choice questions. (Compulsory
Question) [10×1=10]

i) The construction of metals/alloys is always ......................, but the contraction allowances

are always expressed in ...................... measures.
ii) ...................... patterns are generally applied to circular work, like rings, wheels, rims,
gears, etc.
iii) A ...................... is an interface within a casting that is formed when two metal streams
meet without complete fusion.
iv) ...................... are the cracks having ragged edges due to tensile stresses during
solidification.
v) ...................... defect occurs when a portion of the face of a mould lifts or breaks down
and the recess thus made is filled by metal.
vi) A ...................... is a specially designed shape employed to take the place of metal in a
mould.
vii) An open hearth furnace is used chiefly for the production of steel and for refining
purposes. [True/False]
viii) Rough cleaning of castings does not include the removal of gates or risers.
[True/False]
ix) Match the List-I (Processes) with List-II (Production of parts)
List-I (Processes) List-II (Production of parts)

A. Rolling 1. Discrete parts

B. Forging 2. Rod and wire

C. Extrusion 3. Wide variety of shapes with thin

walls

D. Drawing 4. Flat plates and sheets

5. Solid and hollow parts

x) Welding process that requires no direct heat application in the joint:

(a) Thermit welding, (b) Electron-beam welding
(c) Friction welding, (d) Laser-beam welding

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Compulsory
2. a) Facility available at Jadavpur University: Casting, Forging, Welding, Fitting
Machine Tools available at Jadavpur University: Lathe, Shaper, Milling Machine, Drilling
Machine, Grinding Machine, Slotting Machine
In present Covid-19 pandemic situation, there is scarcity in Oxygen and Oxygen cylinder.

Whether is it possible to manufacture oxygen cylinder for medical life support purposes with
these facility and machine tools?

Justify your answer from a view of Mechanical Engineer.

(B Type Medical Oxygen cylinder: Material: Manganese steel, 10.2 Liters water capacity
Fitted with bull nose type valve and neck cap, Valve made of Brass and chrome plated
Working pressure: 150 Kg/cm2 at 15 deg. C, Hydraulic test pressure: 250 Kg. f/cm2 ) [7]

b) Write role of manufacturing sector in GDP (Gross Domestic Product) of our country. [3]

ANSWER ANY FIVE (5) FROM THE FOLLOWING QUESTIONS

3. Which one of the following casting shapes would have least solidification time?
(i) A sphere of diameter D = 25 mm;
(ii) A cylinder with both diameter d and height h = 25 mm;
(iii) A cube with a length of side l = 25 mm. [10]

4. Calculate the ratio of solidification times of two steel cylindrical risers of sizes 36 cm in
diameter by 72 cm height and 72 cm in diameter by 36 cm in height subjected to identical
conditions of cooling. [10]

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5. a) Discuss briefly the influence of water-content on moulding sand properties. [4]

b) What is “Stop-off”? Explain briefly. [2]
c) What is “Stack moulding”? [2]
d) What is “System sand”? [2]

6. a) Write short note on “Moulding sand for non-ferrous castings”. [3]

b) What are the technical aspects of making sound castings? [3]
c) What are ‘Bars’ and ‘Gaggars’? Explain with suitable diagram. [3]
d) What is splash core? [1]

7. a) Calculate the permeability number of sand if it takes 1 min 45 s to pass 2000 cm3 of air at
a pressure of 5.5 g/cm2 through the standard sample. [3]
b) A mould has down sprue whose length is 20 cm and the cross section area at the base of the
down sprue is 1 cm2. The down sprue feeds a horizontal running leading into the mould cavity
of volume 1000 cm3
Find the time to fill the mould cavity? [3]

c) Explain briefly “Flaskless moulding process”. [3]

d) Problem with dry sand moulds is (i) The process is more expensive/(ii) The process
produces castings with defects/(iii) Erosion of the mould takes place/(iv) None [1]

8. a) Explain briefly the following processes :

(i) Swaging (ii) Creep forming (iii) Hot Isostatic Pressing (HIP). [4]
b) Explain briefly the following terms for rolled products:
Bloom, Billet, Slab, Plate, Sheet, Strip, Foil, Bar and Wire. [6]

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