1 ) What is the welding process? Explain different types of welding processes.

ANS :

Welding is a manufacturing process used to join two or more pieces of metal or

thermoplastics by heating the surfaces to their melting points and allowing them to cool and
fuse together.

Metal Inert Gas Welding: (MIG) welding uses a wire electrode that is continuously
fed into the welding gun.

Tungsten Inert Gas Welding: (TIG) welding uses a tungsten electrode to create an
arc between the electrode and the metal being welded.

Stick Welding /Shielded Metal Arc Welding or SMAW): (SMAW) is a process that
uses a consumable electrode coated in flux to create an arc between the electrode
and the metal being welded.

Flux-Cored Arc Welding (FCAW): FCAW uses a wire electrode that is similar to the
one used in MIG welding but is coated in a flux material.

Plasma Arc Welding: (PAW) uses a plasma torch to create an intense arc between
the electrode and the metal being welded.

Electron Beam Welding :(EBW) uses a high-energy beam of electrons to create a

welding arc between the metal being welded and a tungsten electrode.

Laser Welding: (LS)uses a high-powered laser beam to heat and melt the metal
being welded.

2) Explain the brazing process with a sketch. Write its applications and
advantages.

ANS :
Brazing is a metal-joining process that uses a filler metal, called a brazing alloy, to
join two or more pieces of metal.

1. Cleaning: The surfaces of the metal parts to be joined must be cleaned

thoroughly to remove any oil, grease, rust, or other contaminants.
2. Assembly: The parts to be joined are assembled and held in place by fixtures
or clamps.
3. Heating: The assembly is heated to a temperature above the melting point of
the brazing alloy but below the melting point of the base metal.
4. Brazing: The brazing alloy is introduced into the joint and melted by the
heat of the assembly. The molten alloy flows by capillary action and fills the
gap between the two parts.
5. Cooling: The assembly is allowed to cool to room temperature, and the
brazing alloy solidifies, creating a strong joint.

APPLICATIONS : ADVANTAGES :

HVAC systems Strong joints

Aerospace Versatility

Jewellery Cost-Effective

Automotive No Distortion

3) What is the working principle of arc welding?

ANS : Arc welding is a welding process that uses an electric arc to melt and
fuse metal together.

Arc welding uses an electric phenomenon called arc discharge.

An arc discharge is an electric discharge phenomenon of a gas and refers to

current released in air.

When the voltage applied to two spatially separated electrodes is gradually

increased, the air insulation finally breaks and current flows between the
electrodes, emitting bright light and high heat at the same time.

The generated arc-shaped light is called an electric arc or arc.

Arc welding is welding using the heat of an arc as a heat source.

In arc welding, positive voltage is applied to the electrode and negative
voltage is applied to the base material.
This makes an arc occur from the base material to the electrode.
The output current of the arc is about 5 to 1,000 A and the output voltage is
about 8 to 40 V.

The temperature of the arc is about 5,000°C to 20,000°C. The melting

temperature of iron is about 1,500°C. Consequently, the base material and
electrode are heated to a high temperature and fuse together.

4) What are the advantages, disadvantages and applications of metal arc

welding (MAW)?

ANS : Metal Arc Welding (MAW) is a type of arc welding process that uses a
consumable metal electrode and an electric arc to melt and fuse metal parts
together.

ADVANTAGES :

1. Simple welding equipment

2. Portable

3. Inexpensive power source

4. Relatively inexpensive equipment

5. Welders use standard domestic current.

6. Process is fast and reliable

 DISADVANTAGES :

1. Health hazards
2. High initial cost.
3. Requires skilled labour.
4. Limited suitability for certain materials.

APPLICATIONS :

1. In the maintenance & repair industry.

2. Industrial fabrication.
3. Used in weld iron and steel.
4. Also used to weld aluminium,nickel,copper.

5) A neat sketch explaining the gas welding process along with its
applications.

ANS :

Gas welding process is quite simpler compared to arc welding. In this process all
the equipment is connected carefully.

The gas cylinder and oxygen cylinder connected to the welding torch through
pressure regulators.

Now the regulated pressure of gas and oxygen supplied to the torch where they
properly mixed. The flame is ignited by a striker.

Take care the tip of the torch is pointing downward.

Now the flame is controlled through valves situated in a welding torch.

The flame is set at natural flame or carburizing flame or oxidising flame according
to the welding condition.

Now the welding torch moved along the line where the joint was to be created. This
will melt the interface part and join them permanently.

Application:

● It is used to join thin metal plates.

● It can be used to join both ferrous and non-ferrous metals.
● Gas welding is mostly used in fabrication of sheet metal.
● It is widely used in automobile and aircraft industries.
6 ) A neat sketch explaining the spot welding process. Write a few applications of it.

ANS : Spot Welding Process

In the spot welding process, the materials to be welded are overlapped and pressed
between two water-cooled electrodes and a high electric current is passed through
the assembly. The metals in the zone of pressure get heated up to their melting
temperature and the joint so made gets cooled under pressure.

For the spot welding process, the required welding current is about 5000 A and the
voltage between the electrodes is usually less than 3 V. Also, the open circuit
voltage is less than 12 V. To regulate the secondary voltage and current, tappings
are provided on the primary winding of the transformer.

Applications of Spot Welding

● Spot welding is used in various industries such as automotive, aerospace,

metal furniture, electronics, building construction, etc.
● Spot welding is used in high volume production applications.
 ● It is applied for welding of thin sheets.
● Spot welding is also used for fabricating all types of sheet metal structures
where high mechanical strength is required.

7) Explain the working principle of the rolling process. Write its advantages,
disadvantages and applications.

ANS :

Working Principle :

In Rolling operation, the metal strip or the material is to be placed

in between two rollers such that material is compressed by the
opposite forces of the rollers to make the material to a uniform
thickness.The presence of friction between rollers and the strip is
making it pull the strip into the rollers without applying any
pulling and pushing.
By the application of rolling, the length of the material increases
and thickness reduces without any change in the width of the
workpiece.

Advantages :
● By rolling, uniform dimensions of the components can be obtained.
● It uses the same tool in the sense, the same rollers are responsible for the production
of various components.
● Close tolerance is possible for the components in the rolling.
● high-speed production takes place in the rolling.

Disadvantages :

● The cost of equipment is high.

● It is suitable for large scale production only.
● Poor surface finish and thereby we need secondary operations like finishing etc.

Applications :

● Rolling is used for making rods.

● By rolling, Large length cross sections are produced.
● Steel sheets and plates are made by rolling.
● Cement Kilns are produced from rolling only.
● It is used in automotive industries for manufacturing various parts.
8) Explain the working principle of drawing. Write its advantages, disadvantages.

ANS :

Drawing is a common metalworking process performed by manufacturing companies. It’s

able to extend the length of metal by pulling and stretching the metal. It’s called “drawing”
because the machine “draws” the metal towards it. As the metal stretches, it becomes longer
and thinner. Once the desired shape has been achieved, the metal is removed from the
machine.

Types Of Drawings :

Cold Drawing

Sheet Metal Drawing

Bar Drawing

Deep Drawing
ADVANTAGES :

1.Improved Strength of metal.

2.Improved Surface Finish of metal.
3.Cost-Effective.
4.Versatility is in a wide range of applications.

DISADVANTAGES :

1.Limited Complexity of complex & geometric shapes.

2.Requires Skilled Operators.
3.Reduced Ductility of metal .
4.Material Wastes are more after the process.

9) Explain the working principle of the extrusion process. Write applications.

ANS : Extrusion Process:

Working Principle:

Extrusion is a simple compressive metal forming process. In this process, a piston or plunger
is used to apply compressive force at work.

● First billet or ingot is produced.

● This billet is heated in hot extrusion or remains at room temperature and placed into
an extrusion press.
 ● Now a compressive force is applied to this part by a plunger fitted into the press
which pushes the billet towards the die.
● The die is small opening of required cross section. This high compressive force allows
the work metal to flow through the die and convert into the desired shape.
● Now the extruded part is removed from the press and is heat treated for better
mechanical properties.

Application:

● Extrusion is widely used in production of tubes and hollow pipes.

● Aluminium extrusion is used in structure work in many industries.
● This process is used to produce frames, doors, windows etc. in automotive industries.
● Extrusion is widely used to produce plastic objects.

10) Classify the forging operations and its advantages. Explain about a pneumatic
forging machine.

ANS :

Forging is the process in which metals are formed and shaped using compressive forces. The
forces are delivered using hammering, pressing, or rolling.

CLASSIFICATION OF FORGING :

Advantages of forging

● Parts manufactured by forging are stronger

● It offers high ductility
● It is more reliable and less costly
● It refines structure of metal
 ● It offers broad size range of products
● It has great design flexibility

A pneumatic forging machine, also known as an air hammer or power hammer, is a type of
forging equipment that uses compressed air to generate the striking force needed for forging
metal. The machine consists of a hammer-like piston that is driven up and down by
compressed air. The piston strikes a steel or iron workpiece that is placed on an anvil, which
is usually made of a large, heavy block of steel.

UNIT 4 :

1 A) What is force? Explain different types of forces.

Ans : Force: A physical quantity which changes the position of a body is in rest or motion is
called force. Ex; muscle force, pulling force, pushing force, stopping force, punching force,
wind force, water force, weight force, etc;

F=ma where m—mass in kg

 2
a—acceleration m/s

2
Unit for force is kgm/s or N (newton).

Types of forces

Coplanar forces: When all forces are acting in the same plane, they are called coplanar
Forces.

Coplanar concurrent forces: In this system, the line of action of all forces passes through a
single point and forces lie in the same plane. An example is the weight suspended by two
inclined strings.
Coplanar non-concurrent forces: In this system, the line of action of all forces does not
pass through a single point and forces lie in the same plane. An example is the weight
suspended by two inclined strings.

Coplanar parallel like forces: A parallel coplanar force system consists of two or more
forces whose lines of action are parallel and acting in the same direction.

Coplanar parallel unlike forces: A parallel coplanar force system consists of two or more
forces whose lines of action are parallel and acting in opposite directions.

Collinear forces: Collinear forces are forces that have a common line of action, i.e. the line
of action of the forces lie along a single straight line.

Non-coplanar forces: When forces are not acting in the same plane, they are called
non-coplanar forces.

Non-Coplanar concurrent forces: In this system, the line of action of all forces passes
through a single point and forces lie not in the same plane

Non-coplanar parallel like forces: A parallel non- coplanar force system consists of two or
more forces whose lines of action are parallel and acting not in the same plane

Spatial forces: Spatial forces are neither concurrent nor parallel.

4 .Find the resultant of forces and point of application from A in the figure
given below.

5. Find the magnitude of reactions at B and D from the figure given below.
Explain following terms with suitable sketches:

1. Force components : The components of a force represent the combined

vertical and horizontal forces that combine to make the resultant force F.
 2. Resultant : The resultant of force is described as the total amount of force
acting on the object or body along with the direction of the body.

3. Couple : A couple is a pair of forces, equal in magnitude, oppositely

directed, and displaced by perpendicular distance or moment.

4. Moment : The moment of a force depends on the magnitude of the force

and the distance from the axis of rotation. The moment of a force about a
point is the product of the magnitude of the force and the perpendicular
distance of the line of action of the force from the point.

5. Equilibrium : A force is a vector quantity which means that it has both a

magnitude (size) and a direction associated with it. If the size and direction of the
forces acting on an object are exactly balanced, then there is no net force acting on
the object and the object is said to be in equilibrium.