Manufacturing Processes (22446)

Remember Level Question………. (2Marks)

Unit -1
1. List types of chips produced in machining processes.
1. Continuous chip
2. Discontinuous chip
3. Built-up chip

2. List any four accessories used on Lathe.

1. Chuck
2. Face plate
3. Angle plate
4. Driving plate
5. lathe carriers or dogs
6.lathe centre

3. Explain in short mechanics of chip formation.

As the tool makes contact with the metal, it exerts a pressure on it.
It results in the compression of the metal near the tool tip. This causes shear-type deformation of the
metal.
Metal flows in the form of chips (Plastic Deformation ).

4. Enlist elements of tool signature of single point cutting tool.

(i) Back rake angle ;
(ii) Side rake angle ;
(iii) End relief angle ;
(iv) Side relief angle ;
(v) End cutting edge angle ;
(vi) Side cutting edge angle ;
(vii) Nose radius.

5. Designate a tool 8 – 10 – 6 – 6 – 5 – 10 – 0.8 signature in ASA system.

1. Back rake angle-8
2. Side rake angle-10.
3. End relief angle-6.
4. Side relief angle-6
5. End cutting edge angle-5
6. Side cutting edge angle-10.
7. Nose radius-0.8 mm.

6. State basic parts of center lathe.

Bed Tail stock Head stock Carriage Feed mechanism
7. List any four operations performed on lathe machine.
1. Facing
2. Plain turning
3. Step turning
4. Taper turning
5. Drilling
6. Reaming

Unit – 2
1. Define feed and speed in a shaping machine.
1) Feed: Feed (S) is the relative movement of the work or tool in a direction perpendicular to the axis
of reciprocation of the ram per double stroke. It is expressed in mm per stroke.
2) Speed: In a shaper, the cutting speed is the speed at which the metal is removed by the cutting tool
in a period of one minute.

2. Give classification of shaping machines.

1 . According to the type of mechanism used for giving reciprocating motion to the ram :
(a) Crank type
(b) Geared type
(c) Hydraulic type.
2. According to the position and travel of ram :
(a) Horizontal type
(b) Vertical type
(c) Travelling head type.
3. According to the type of design of the table :
(a) Standard shaper (b) Universal shaper
4. According to the type of cutting stroke:
(a) Push type (b) Draw type.

3. List different shaping operations.

1. Horizontal cutting,
2. Vertical cutting,
3. Angular cutting, and
4. Irregular cutting.
5. Machining of Slots, grooves, Keyways
6. Machining Splines or cutting gears.

4. Enlist the types of shapers.

(a) Crank type
(b) Geared type
(c) Hydraulic type
(d) Horizontal type
(e) Vertical type
(f) Travelling head type.
 Unit – 3
1. List any four materials used for pattern making.
1. Wood
2. Metal
3. Plastic
4. Plaster
5. Wax

2. List any four casting defects.

1. Gas Porosity: Blowholes, open holes, pinholes.
2. Shrinkage defects: shrinkage cavity.
3. Mold material defects: Cut and washes, swell, drops, metal penetration, rat tail.
4. Pouring metal defects: Cold shut, misrun, slag inclusion.
5. Metallurgical defects: Hot tears, hot spot.
3. Enlist types of moulding sand.
Natural Sand Synthetic Sand
Green Sand Dry Sand
Loam Sand Facing Sand
Parting Sand Floor, black or backing Sand
Core Sand

4. State the various elements of gating system in moulding process.

1. Pouring basin. 2. Sprue.
3. Sprue base or well. 4. Runner.
5. Skim bob. 6. Gates and foringates.
7. Choke. 8. Riser.

5. Elaborate why the section of a sprue reduces downwards.

A sprue section reduces downwards to a smaller size at its bottom will create a choke which will help
keep the sprue full of molten metal.

6. List types of electric furnace.

Three Types of Electric furnaces:
1. Induction heating furnace.
2. Resistance heating furnace.
3. Arc furnace.

7. Write the indications of following color in coding of pattern.

i) Black : Surface to be left Un machined
ii) Red : Surface to be machined
iii) Yellow : Core Prints
iv) Red strips on yellow background. : Seats for loose piece

8. Name any four types of pattern.

1. Solid or Single piece pattern
- Flat face or flat block pattern
- Symmetrical pattern
2. Split piece or Two piece pattern
- Three piece pattern
 3. Loose piece pattern
4. Gated pattern
5. Pattern with follow board

9. Name at least two products manufactured by vaccum forming.

Hot water bottles, refrigerator door liners, cosmetic containers, trays, cups.

Unit - 4
1. State the applications of rolling.
Different types of shapes are formed such as I-section, T-section, L-section, Channel section
Special section such as railway wagon wheels is produced by rolling.
Bars of all shapes, rods, sheets etc.
Several metals are rolled into variety of shapes.

2. State applications of extrusion process.

Rods, tubes, Structural shape, Aircraft parts, cans, lead covered cables, various aluminum bracket

3. State jumping operation.

Upsetting or jumping or heading is the process through which the cross section of metal piece is
increased with a corresponding reduction in its length

4. Define forging Process.

Forging is the process by which heated metal is shaped by the application of sudden blows or steady
pressure and characteristics of materials.

Unit – 5
1. State the applications of TIG welding.
1. Al-alloys, Cu-alloys, Mg-alloys, Nickel alloys, Zirconium alloys, Titanium alloys, Beryllium
alloys, Refractory meta.ls, Carbon steels, alloy steels and Stainless steels.
2. Space ship Vehicles, Motor chamber welding.

2. Differentiate between soldering and brazing.

3. State the four advantages of MIG welding.

Advantage:
 No flux is required
High welding speed
Increased corrosion resistance
Easily automatic welding
No slag formation
More suitable for welding thin sheets

4. Define brazing.
• Brazing is essentially similar to soldering, but it gives a much stronger joint than soldering.
• Brazing is a soldering operation using brass as the joining medium.
• Use of a harder filler material, commercially known as spelter
• The brazing operation is simply a form of hard soldering using a copper-zinc alloy.

5. Name the fillers used in soldering.

1. Lead tin alloy solder 4. Lead Antimony tin alloy solder
2. Tin Zinc solder 5. Lead Silver solder
3. Cadmium silver solder

6. List any four welding defects and their causes.

(i) Insufficient fusion
(ii) Porosity
(iii) Spatter
(iv) Undercut

7. State the four advantages of plasma arc welding.

Advantage:
1. Uses low current than TIG & MIG
2. Distance between electrode & work piece does not affect arc formation.
3. High penetration rate.

8. Give two practical application of spot welding.

Automobile, air planes, steel cabinets, boxes, cans and furniture.
 Understand Level Question……… (4 Marks)
Unit -1
1. Explain the mechanics of chip formation with neat diagram.

• A wedge-shaped
shaped tool is made to move relative to the work piece.
• As the tool makes contact with the metal, it exerts a pressure on it.
• It results in the compression of the metal near the tool tip. This causes shear-type
shear deformation of the
metal
• As the tool advances into the work piece, the material in front of tool is compressed.
• When the compression limit of metal is exceeded, it is sepseparated
arated from the work piece.
• Metal flows in the form of chips (Plastic Deformation ).
• The material ahead of it is sheared continuously along a plane called the ‘‘Shear plane’’.

2. Write down the steps involved for internal thread cutting on lathe machine.

Procedure:
1. Check the size of raw material given and ensure the size.
2. Hold the work pieces in the chuck and tight it properly.
3. Clamp the tool on tool post properly and check the centre of work piece with cutting tool tip.
4. Do the facing operation
ation by giving cross feed to the cross slide and reduce the length.
5. Do the turning operation by giving longitudinal feed to the carriage and reduce the length.
6. Two or three pass can be given for the turning operation.
7. Remove the work piece and hold in chuck on the other side and do the turning operation for the
remaining work piece.
8. Engage the back gear mechanism to reduce the speed of the work piece.
9. Check the pitch required, calculate the tumbler gear, and engage it with head stock.
10.
0. Move the carriage towards tail stock and make a mark on the dial.
11. Give small depth of cut and engage the half nut so that the carriage will move automatically
towards head stock and cut the v-thread
v on the work piece.

3. Draw a neat sketch and explain the accessory used to support long work.
 Steady Rest -
• It is also called as centre rest.
• This rest remains stationary at one position with respect to tool.
• It consists of cast iron frame and three adjustable jaws.
• The frame is made of two parts, which are hinged at one end to give facility of easy setting and
removing of workpiece.
• The bottom portion of rest has grooves corresponding to the lathe bed ways and can slide on it.
• Rest can be clamped at any desired position where support is required.
• All the three jaws can be adjusted radially by using setscrews to accommodate the job of any diameter.

4. Write down the basic parts of a lathe machine with their proper functions.
Its major parts are
Bed Tail stock Head stock Carriage Feed mechanism
1. Bed -
- It is the base or foundation of lathe. It is a heavy rigid casting made in one piece.
- In majority of case beds are made of grey Cast iron.
- It holds and supports all other parts of lathe.

2. Head stock –
- It is permanently fastened to the inner ways at the left hand end of the bed.
- It serves to support the spindle and driving arrangement.
- All lathe receive power through head stock. It have step cone pulley or gear head drive.

3. Tail stock –
- It is situated at right hand end of the bed. It is used to support the right hand side end of work.
- It is also used for holding and feeding the tools such as drills, taps, reamers etc.
- Its main function is to hold the dead Centre so that long work piece can be supported between the two
centre.

4. Carriage - The carriage controls and supports the cutting tool

5. Feed mechanism -
- It is employed for providing various feeds (longitudinal, cross and angular) to the cutting tool.

5. State various types of chips. Explain any one with neat sketch.
1. Continuous chip 2. Discontinuous chip 3. Built-up chip
 Continuous chip :
- Produced while machining more ductile materials.
- Continuous ribbon like chips are produced
- provide good surface finish, stable cutting
- It may injure operator & this chips are difficult to Handle.

Discontinuous chip :
- Produced while cutting more brittle materials
- Discontinuous segments like chips are produced
- Unstable cutting and better surface finish.
- Easy to handle and collect

Built-up chip :
- Produced while cutting machining ductile material
- Work material gets welded to cutting edge of tool.
- Causes due high local temperature extreme pressure and high friction.
- This forms built up edge (BUE)
- It results in – Rough surface finish, vibration
- It protects the cutting edge of tool.

6. Explain with neat sketch thread cutting operation on lathe machine.

- Threading is an operation of cutting helical grooves on the external cylindrical surface of the work
piece.
- In this operation, as shown in the work is held in a chuck or between centres and the threading tool is
fed longitudinally to the revolving work.
- The longitudinal feed is equal in the pitch of the thread to be cut.
7. Explain various drilling machine operation with neat sketch.(at least three)
Reaming
It is the operation of finishing an existing hole very smoothly and accurately in size.
A drill will not produce a hole having sufficiently good qualities of finish and accuracy for many
purposes.
Therefore, when a very accurate, smooth hole is required the hole is first drilled a little undersize.
Then it is reamed to the correct size.
A reamer is a multi-tooth cutter which rotates and moves linearly into an already existing hole.

Boring
It is an operation of enlarging an existing hole.
When a suitable size drill is not available, initially a hole is drilled to the nearest size and using a
single point cutting tool,
The size of the hole is increased By lowering the tool while it is continuously rotating, the size of the
hole is increased to its entire depth.

8. Explain single point cutting tool signature.

(i) Back rake angle ;
(ii) Side rake angle ;
(iii) End relief angle ;
(iv) Side relief angle ;
(v) End cutting edge angle ;
(vi) Side cutting edge angle ;
(vii) Nose radius.
9. Draw a neat sketch of radial drilling machine and label the parts.

10. Define following terms with reference to a single point cutting tool:
i) Back rake angle ii) Side rake angle
iii) End relief angle iv) Side relief angle
Back rake angle.
It is the angle between the face of the tool and a line parallel to the base of the tool and measured in a
plane (perpendicular) through the side cutting edge.

Side rake angle.

It is the angle between the tool face and a line parallel to the base of the tool and measured in a plane
perpendicular to the base.

End relief angle.

It is the angle between the portion of the end flank immediately below the end cutting edge and a line
perpendicular to the base of the tool.
Angles range from 5° to 15°

Side relief angle.

It is the angle between the portion of the side flank immediately
immediately below the side cutting edge and a line
perpendicular to the base of the tool.

11. Explain cutting parameters of lathe machine with their SI units.

1. Cutting speed
It is defined as the relative surface speed between the tool & the job. It is expressed in m
m/min
Or
It is the amount of length of work material that will pass the cutting edge of the tool per unit time.

2. Feed
It is the distance the tool moves towards work for each revolution of the work.
It is expressed in mm per revolution.
3. Depth of cut
It is the thickness of the layer of metal removed in one cut or pass measured in a direction
perpendicular to the machined surface.
 Depth of cut = D1 – D2 ……..mm
2

4. Machining time Calculation

Time taken for a complete cut = L ……. Minutes
SxN
where ,
L = Length of the work in mm
S = Feed of Job per revolution in mm / revolution
N = RPM of Work piece.

12. Explain any two types of feed in connection with the working of slotter machine.
o Longitudinal feed: The table moves perpendicular to the column, either toward or away from its face.
o Cross feed: The table travels parallel to the column's face.
o Circular feed: The table rotates about the vertical axis, effecting circular feed.
o Power (Automatic) Feed Mechanism: employs a bull gear with a cam groove housing a roller.

13. Explain any two cutting parameters of drilling mahines.

1. Cutting speed.
It is the peripheral speed of a point on the surface of the drill in contact with the work piece. It is usually
expressed in metres per minute.

2. Feed (f).
It is the distance the drill moves into the work at each revolution of the spindle.
It is expressed in mm/rev. It may also be expressed as feed per minute.
Feed Speed = F x N ……… mm/min

Unit -2
1. Explain how size and specifications of a slotter are to be designated.
OR
Express Specifications of Slotting machine.
1. Maximum stroke length 300 mm.
2. Height between table and tool head 450 mm.
3. Maximum diameter of work piece that can be machined 900 mm.
4. Diameter of table 500 mm.
5. Longitudinal feed given to the table 450 mm.
6. Transverse feed given to the table 350 mm.
7. Face of the head 575 x 250 mm.
8. HP required: 2 HP.

2. Explain angular shaping with neat sketch.

This operation is used for machining of inclined surfaces, bevelled surfaces & dovetails etc.
In this down feed of the tool is used.
The apron top is swivelled in a direction away from the surface to be machined.
Also the tool head is swivelled.
In other way job is set inclined direction.

3. Explain slotted time quick return mechanism with neat sketch.

Working of quick return mechanism

1. The mechanical ram drive is a slotted arm quick return motion mechanism.
2. The slotted arm is pivoted at its lower end to the column & its upper end is connected by a link to an
adjustable ram block which is secured to the ram block.
3. The power from the electric motor is transmitted to the bull gear through gears & bull gear pinion.
4. A pin fits freely into a hole in the bull gear block which can slide in the slot of rocker arm.
5. As the bull gear rotates it carries the pin in a circular path with the help of the crank.
6. This makes the rocker arm to swing back & forth about its stationary pivot ‘C’.
7. Thus rotary motion of the bull gear is converted into reciprocating motion of the ram with the cutting
tool.
5. Explain the basic parts of a slotting machine with neat sketch.
Explain vertical Shaper with neat Sketch.

1. Base :
- It is also known as bed and is a heavy cast iron construction.
- It acts as a support for the column, the driving mechanism ram, table and all other fittings.
- At its top it has horizontal ways, along which the table is moved.
2. Column :
- It is also made of cast iron.
- It acts as housing for the complete driving mechanism.
- Its front face has guide ways for the reciprocating of the ram.
3. Table :
- On slotting machines, usually a circular table is provided.
- On the top of the table are provided T-slots to clamp the work or facilitate the use of fixtures etc.
- The table can be moved is horizontal plane by two perpendicular cross-slides.
4. Ram :
- It moves in vertical direction between the vertical guide ways provided in front of the column.
- The ram supports the tool head to which the tool is attached.
- The cutting action takes place during the downward movement of the ram.

6. Explain with neat sketch working principle of shaping.

1. The shaping process can be defined as a process of removing metal from surfaces in horizontal,
Vertical & angular planes by the use of Single point cutting tool
2. Tool is held in a ram that reciprocates across work piece held on the table of the machine.
3. In the shaper the cutting tool has a reciprocating motion & it cuts only during the forward stroke.
4. The regular feed is obtained by moving worktable automatically at right angles to the direction of
cutting tool.
7. Classify the slotting machine and explain the working principle of slotting machine.
1. Punch Slotting Machine
a. Heavy duty
b. Large casting frame
c. Large Stroke

2. Production slotting machine

a. General Production machine
b. Common Type
c. Mechanism – Slotted Disc, Connecting Ram

3. Precision Tool room Slotting machine

a. Light duty machine
b. High Speed
4. Key Seater
a. Used for machining keyways

8. Explain the function of following parts in shaper:

i) Cross rail ii) Table
iii) Ram iv) Tool head
Cross-rail :
- It is mounted on the front vertical guide ways of the column.
- It has two parallel guide ways on its top in the vertical face that are perpendicular to the ram axis.
- The table is raised or lowered to adjust different size of jobs by rotating an elevating screw
- It causes the cross-rail to slide up and down on the vertical face of the column.

Tool – Head :
- It holds the tool rigidly.
- It is clamped firmly to the front of the ram.
- It Consist of Vertical tool Slide & apron.

Table :
- It is made of cast iron and is rectangular in shape.
- It has T-slots on its top surface.
- The table can be moved upward, downward or sideward with the help of elevating screws and other
feed handle.
- The Job is supported on the table with the help of Vice.

Ram :
- It is a reciprocating member which reciprocates on the guide ways provided above the column.
- It carries a tool-slide on its head and a mechanism for adjusting the stroke length.
- Ram is driven by a quick return mechanism.

9. Explain the working principle of standard slotting machine with neat sketch.
Explain working principle of standard slotting machine with neat sketch.
In a slotter the ram holding the tool reciprocates in a vertical direction the work is mounted on the table
remains stationary & provides the feed.
The slotting process can be defined as a process of removing metal from surfaces in Vertical planes by the
use of Single point cutting tool
Tool is held in a ram that reciprocates across work piece held on the table of the machine.
In the slotter the cutting tool has a reciprocating motion & it cuts only during the downward stroke.
The regular feed is obtained by moving worktable automatically at right angles to the direction of cutting
tool.

10. Explain keyway machining on slotting machine.

External and internal grooves can be cut on a slotting machine.
Slotters are used especially to cut internal grooves that are difficult to cut on other machines.
The procedure is as follows -
Marking the keyway with the help of a scriber or marking block.
Then clamp the work-piece with the help of a fixture or clamps or vice
Clamp the keyway tool on the tool holder.
Match the marking portion with the center of the tool.
Define the length and position of the strokes.
Start the machine and give feed gradually by hand.
Measure the keyway with the help of a slip gauge.
Continue the operation until the keyway is finished.

Unit -3
1. State two advantages and disadvantages of centrifugal casting. Write four applications.
Advantages of centrifugal casting :
1. Quick and economical than other methods.
2. In this process the use of risers, feed heads, cores etc. is eliminated.
3. The ferrous as well as non-ferrous metals can be casted.
4. Good surface finish.

Dis advantages :
1. Metallic composition of alloys is not uniform throughout the casting.
2. Casting must be symmetrical.
3. Limited to small intricate castings.

Application - Gun barrels, Bushing, lamp Post, engine cylinder liner, Bearings, pipes.

2. Draw a neat sketch of Gating system. State the functions of any four elements.
 The basic elements of the gating system are :
1. Pouring basin. 2. Sprue.
3. Sprue base or well. 4. Runner.
5. Skim bob. 6. Gates and for In gates.
7. Choke. 8. Riser.

1.Pouring Basin – It is the part of gating system that receives molten metal from the pouring vessel.
2.Sprue – Pouring basin attaches to the Sprue which is vertical part of gating system.
Another end of the sprue is attached to the runner.
Its cross section may be square, rectangular, or circular
3.Runner – Runner is the horizontal portion of gating system at which other end of sprue is attached.
4.Gates – These are the openings through which the molten metal enters the mould cavity.
5.Riser – It is the passage through which molten metal
rises up after filling the mould cavity.

3. State importance of colour scheme for pattern. Illustrate a common colour scheme.
* Importance of Color Coding *
1. To identify main part of the pattern from remaining parts.
2. To identify loose pieces, core prints etc.
3. To show the part to be machined.
4. To show the part to be left unmachined.
5. To identify the type of metal to be casted.

4. Write down the method used for following product :

(i) credit card
(ii) carrying case
(iii) hollow cylinder
(iv) knobs
(i) credit card - Calendering
(ii) carrying case – Injection Moulding.
(iii) Hollow cylinder – Blow Moulding
 (iv) Knobs – Injection Moulding
(v) Plastic jug - Injection Moulding
(vi) PVC sheet - Calendering
(vii) Plastic bottle – Blow Moulding
(viii) Refrigerator door liners – Vacuum forming.

5. Determine different defects in casting. State their causes and remedies (six).
1. Blow hole
Due to entrapped bubbles of gas during solidification

Causes
1. Excessive moisture.
2. Low sand permeability.
3. Fine sand grains.

Remedies
1. Control of moisture content.
2. Use of rust free chills, chaplet and clean inserts.
3. Bake cores properly.

Drop
It occurs when the mould cracks and pieces of sand fall into molten metal.

Causes
i) It is caused due to low strength
ii) soft ramming
iii) Insufficient reinforcement of hanging section

Remedies
1. Increase green strength of sand mould.
2. Provide harder ramming.
3. Provide adequate reinforcement to sand by using nails and gaggers.

Mis-run & Cold shut

When molten metal fails to fill the entire cavity of the mould, incomplete casting is obtained.

Causes
i) Too thin sections and wall thickness.
ii) Improper gating systems.
iii) Damaged pattern.
Remedies
i) Use hotter metals
ii) Frequent inspection and replacement of pattern.
iii) Proper design of gating and riser

Swell
enlargement found on the casting surface due to liquid metal pressure.

Causes
1. improper ramming
2. low strength of mould
3. Pouring the metal too rapidly

Remedies
1. Proper ramming of sand
2. uniform flow of molten metal into the mould

Fins and flash

It is a thin metal projection on casting.
Causes
i) incorrect assembly of moulds and cores
ii) Improper clamping of the mould
iii) excessive rapping of the pattern
iv) insufficient weight on the top part of the mould

Remedies
i)These can be controlled by adopting proper moulding, gating and melting techniques.
ii) insufficient weight should be placed on the top part of the mould

Hot tears (Hot Cracks)

internal or external cracks resulting immediately after the solidification of metal

Causes
i) abrupt changes in section
ii) poor design
iii) incorrect pouring temperature

Remedies
1. abrupt change in section should be avoided
2. Pouring temperature should be correct
3. There should be even rate of cooling
6. Explain calendering process of plastic.
1.This
This process is used for making plastic films and sheets.
2.In
In this process a heated doughy paste of plastic compound is passed through a series of hot rollers,
roll
where it is squeezed into the form of thin sheet of uniform thickness.
3.Thickness
Thickness is controlled by a combination of squeezing & changing the speed of the finishing rolls.
4.The
The finished product is cooled by passing through the water cooled roll which is called as chilling roll.
5.The
The thickness of the sheet depends on the spacing between the rollers that stretch the plastic.
6.The
The first roll act as a feeder, the second as a metering device and third roll gap sets the thickness of the
gradually cooling plastic which is then wound onto a drum.
Advantage: 1. Cost is very low 2. Materials are isotropic
Disadvantage: 1. Very thin film is not possible 2. It is limited to sheet material
Application: Vinyl film, sheet, Coating & vinyl floor tile, PVC Sheet.

7. List out safety precaution to be taken in foundry shop.

1.Protective
Protective head gear, safety foot ware, protective glasses must be worn in the working area.
2.All
All precautions taken against fire, must be available here.
3.Molten
Molten metal should not come in contact with water
water as it may cause explosion.
4.In
In the shop floor adequate ventilation must be provided.
5.Burn
Burn injury cases must be treated immediately by medical personnel.
6.Have
Have a dry pile of sand & shovel ready to put out fire in control.
7.Have
Have sand bed under all areas.
8.Usee long handed pliers (Tongs) & rod.
9.Plan emergency exit
10. First Aid & Training

8. Explain centrifugal casting method with neat sketch.

 True centrifugal casting -
In this method the axis of rotation of the mode and that of the casting are the same.
The molten metal is ford into a revolving mould.
The centrifugal force throws metal towards the outer walls.
The outside of the mould is water cooled therefore the metal solidifies and forms a hollow casting.
The axis of rotation is generally horizontal but can be vertical for short work peice .
The inner surface of the casting remains cylindrical.

9. Differentiate between hot chamber & cold chamber die casting.

10. Explain construction and working of cupola furnace.

Construction
1. It consist of a cylindrical steel shell with its inner side is coated with heat resisting fire brick.
2. Into which raw materials and fuel are charged at the top.
3. Air for combustion of fuel is supplied through one or more rows of tuyeres.
4. Spark arrester at the top allows only smoke to escape from chimney.
Working –
1) First operation is to light the fire at the bottom. When the fire is burning strongly, coke is added
gradually till the level above tuyeres.
2) This coke act as a bed for the charge of metal, flux & coke
3) When the cupola is filled level up to the charging door the Air blast is put on.
4) Due to this combustion near tuyeres increases rapidly & it produce high heat.
5) The gases of combustion move upward & pass over the metal & coke.
6) This gases gives heat to the metal.
7) Due to this metal starts melting & trickles down (flows down) through coke.
8) Finally collects at the bottom of the cupola.
11. Explain any four properties of Moulding sand.
1. Porosity or Permeability:
- When hot molten metal is poured into the sand, steam and other gases are evolved.
- The sand therefore should have sufficient permeability to allow these gases, steam to escape
- Otherwise, pores and gas holes are caused in the casting.

2. Refractoriness:
- The sand should be capable of withstanding high temperature, without melting or softening.
- Better casting surface is obtained and cleaning of casting becomes easy.

3. Cohesiveness:
- It is the property by which sand particles stick together.
- When water is mixed in the sand it should provide sufficient bond or strength to hold together to retain
shape of the mould, even after the mould is poured.

4. Plasticity:
- It is the property of the sand to acquire a shape under pressure and to retain that shape when pressure is
removed. This property of sand gives good impression of the pattern in the mould.

12. Explain with neat sketch the injection moulding.

1. It is very commonly used for thermoplastic plastics.
2. The powdered plastic compound is first heated to drive off moisture. and then fed into the hopper.
3. When the ram is drawn back, some of the powder drops down into the chamber.
4. After closing the mould the ram is moved forward, applying pressure behind the powder.
5. This compresses the material and forces it forward through the thin space left around the heated
torpedo.
6. Due to heating & pressure applied in heating chamber material gets softens and is forced into the water
cooled mould through the nozzle.
7. After the plastic has been cooled and sufficiently hardened in the mould, the mould is opened and the
produced part knocked out.
12. Explain blow moulding process with neat sketch. State its advantages, limitations and
applications also.

1. In this process a hot tube of plastic called as Parison is placed between the two part open mould.
2. The two parts of the moulds move towards each other so that mould closes over tube.
3. The tube gets pinched off & welded at the bottom by the closing moulds.
4. The tube is then expanded by internal pressure of hot air injected into it.
5. This forces the tube against the walls of the mould.
6. The component is cooled & mould opens to release the component.
Advantage:
1. Tool & die cost is low
2. High product rate
Disadvantage:
1. Only hollow tubular parts can be produced
2. Hard to control thickness
Application:
Beverage bottle, tubes, plastic containers

13. Explain the processes of sand preparation & sand conditioning.

STEPS INVOLVED IN SAND PREPARATION
l. Remove, from sand grains all foreign particles such as fins, nails, etc. by passing it through a sieve or
by magnetic separators.
 2. Mix the sand ingredients in sand mixing machines.
3. Continue mixing or mulling till there is uniform distribution of ingredients.
4. In the next step, treat the sand by the aeration process. Aeration makes sand Buffy, and easy to
handle. Aerated sand produces better moulding results.
7. List the different properties of plastic.
1. Light in weight.
2. Easy workability. Easy to shape and mould.
3. Highly resistant to corrosion.
4. Highly resistant to abrasion., moisture and greases.
5. Good thermal and electrical insulators.
6. Good strength and rigidity.
7. Absorbent of vibrations and sound.
8. Good resistant to most of the chemicals.
9. Impermeable to water.
10. Low fabrication cost.

8. Differentiate between thermo setting plastic & thermoplastics.

 Unit -4
1. Explain cold rolling, a four high rolling mill is usually used.
1. It consists of four horizontal rolls, two of smaller diameter and two of large diameter roll are
arranged directly one over other.
2. The larger diameter rolls are called back-up rolls and their main function is to prevent deflection of
smaller rolls. If deflection occurred it will cause thickening of sheets at the centre.
3. The smaller rolls are known as working rolls and they are the rolls which concentrate the total
rolling pressure over the metal.
4. These mills are generally used for subsequent rolling of the slabs. The common products of these
mills are hot or cold rolled sheets and plates.
5. Application: 1. Rolling of Slab 2. Hot rolled & Cold rolled sheets 3. Rolling of Armor

2. Explain hot and cold rolling. State their applications.

# Hot Rolling #
1. Hot rolling is metal working process in which metal is heated above recrystallization temperature to
plastically deform it in the Rolling operation.
2. The hot metal is passed between two rolls to flatten it. In hot rolling the coarse grains are converted into
smaller grains.
3. It is used for heavy or thick section surface finish will be poor but Mechanical properties will be
uniform.
4. In this process grains remains uniform even after rolling.
Application - By the process semi finished products like blooms blades are produced structural shapes,
Bars, Channel are also produced

# Cold Rolling #
1. Cold rolling is a process which passes metal through roller at temperature below Re crystallization
temperature.
2. In cold rolling grains will be elongated after rolling.
3. As a metal is at room temperature it is less malleable so load required for deformation is more.
4. Cold rolling is used for converting small sections plate
plate to sheets to bar foils wires.
5. It gives good surface finish and reduced mechanical property.
Application - It is used for producing finished items like sheet flats & foils.

3. Explain open and closed die in forging operations.

Open die forging
1. In open die forging the workplace is pressed between two flat surfaces.
2. It is also known as hammer forging or flat die forging.
3. The top die is attached to the ram of press and the bottom die is attached to the press bed in press
forging & to the hammer anvil
nvil in hammer forging.
4. As the work piece is pressed or Hammered material freely deforms under the flat surface.
5. Open die forging generally used to preshape the metal for further operation.
6. Open die forging does not fully control the flow of metal so operator
operator must adjust position of workplace
between the blows.

Closed Die Forging

1. In closed by forging cavities or impression are cut in the Die block.
2. The compressive force is applied on material the metal flows into and Fills the die cavity
cavit to take final
shape.
3. When the pairs of die approach to each other for completing the forging the excess metal is squeeze out
of cavity which is called as Flash.
4. But in true closed die forging no flash is formed. The workplace is completely surrounded by dies.
5. In this forging proper control of volume of material is important to avoid over filling.
4. Explain with sketch upset forging operation.
Machine forging or upset forging
These process involves upsetting operation so it is called as the upset forging it is also known as hot
heading.
In machine forging the material is plastically deformed by the squeeze pressure into the shape provided by
dies in forging machine.

It consist of applying pressure longitudinally on a hot bar gripped firmly between grooved dies. Usually
such upsetting is done at the end of the bar.

The equipment used for doing this type of forging is known as the forging machine or upsetter which
provide the pressure in horizontal direction.

5. Explain direct and indirect extrusion. State their advantages and disadvantages.
Direct Extrusion
1. In this process a billet (piece of metal) of the material to be extruded is placed in a container.
2. At one end of the container is fixed a die while from the other end the metal is forced to flow through
the die by hydraulically driven ram through a follower pad.
3. The problem of friction is more in this process because of their higher extrusion temperatures.
4. To reduce this friction lubricants are to be used. The extruded rod is supported on a run-out table.
5. In this process metal is extruded in the direction of applied force hence it is known as direct or forward
extrusion.

Advantage:
Process is relatively fast
Large variation is possible
Equipment is simple
Disadvantage:
Discard & Surface Impurity are produced
Application: Frames, Door in automobile.

1. In this process the metal is surrounded fully by the cylinder. The ram which contain the die is the
hollow plunger or ram.
2. It is called as a backward or indirect or inverted because of the opposite direction of the flow of metal
to that of ram movement.
3. Thus, the billet in the container remains stationary and hence no friction.
4. Hollow plunger presses the material against the back wall of closed chamber & thus metal is extruded
back into the plunger.
 5. Surface quality is good as there is no heat cracking. Less force is required due to less friction.

Advantage:
1. Force required is less
2. Less friction
Disadvantage:
1. Ram is weak due to hollowness
2. Complex equipment
Application:
Tubes, pipes, Channel , Circular, Different section.

6. List the types of rolling mills and its applications.

Classification
1. According to the number of rolls in the stand
•Two high rolling mill
•Three high rolling mill
•Four high rolling mill
2. According to product rolled
•Blooming and slabbing mill
•Billet mills
•Rail and structural mills
•Section Mills
3. According to the arrangement of Rolling stand
•Looping Mill
Continuous mill
Application :
• It is used for mass production of threaded parts like screw, bolts etc.
• Gears can be cut on gear blank by rolling process.
• Construction material, roofing panels, partition beams, railroads etc. are rolling product.
• It is used to manufacture various parts in automotive industry.
• Steel sheets, plates are made by rolling process.

Two High rolling mill Three High rolling mill Four High rolling mill
7. Differentiate between open die forging and closed die forging.

8. Compare hot rolling with cold rolling.

9. Compare Hot working & Cold Working

 Unit -5
1. Explain with neat sketch laser beam welding.
• The laser beam is high energy resource to heat & to melt the metals to be joined.
• Laser beam is produced by capacitor discharge into Xenon tubes. The intense light is directed to pass
into ruby crystal.
• A laser beam is produced inside the 'Ruby crystal'.
• Silver coated mirrors are fitted internally in both sides of crystal. One side mirror has tiny hole to
allow laser beam to focus out.
• Flash tube filled with Xenon inert gas is wrapped around ruby crystal.
• Flash produces thousand flashes per second.
• Capacitor is provided for storage of electrical energy and supply high voltage to flash tube.
• Chromium atoms of ruby crystal are exited. Due to heat generation light energy is reflected mirror to
mirror.
• And again chromium atom gains energy to form a narrow beam of coherent light, which comes out
through the tiny hole of ruby crystal's mirror.
• This narrow beam of laser is focused by focusing lens to work piece as a concentrated beam of light.

2. Explain with neat sketch the working principle of MIG.

1. These process is known as metal inert gas welding.
2. It involves welding of metals using consumable metal electrode in an inert gas atmosphere.
3. The arc is produced between the metal electrode and the work piece.
4. The electrode is in the form of continuous wire which is fed into the arc.
5. Electrode holder is used which have passage for wire electrode and for supply of inert gas.
6. To shield the electrode, metal from oxidation.
7. Wire fed is adjusted by the speed of motor of wire feed reel.
8. The speed is same as speed of melting & depositing of metal.
9. Usually DC supply is used.
10. Inert gases like Argon, Helium, CO2 are used for shielding.
11. Current Ranges from 100 to 400 ampere.
12. Usually copper coated coil wire are used as electrode.
3. Compare between soldering and brazing.

4. Differentiate between TIG and MIG welding.

 Apply Level…….. (6Marks)
Unit -1
1. Calculate the machining time for a steel drill 10 mm diameter to penetrate a 18 mm thick
steel plate. Assume a feed of 0.2 mm/rev. and cutting speed for steel as 20 m/min.

2. Explain Taper turning operation on lathe machine with neat sketch.

- This method is used for small tapers only (the amount of set over being limited).
- It is based upon the principle of shifting the axis of rotation of the work piece, at an angle to the axis,
and feeding the tool parallel to the lathe axis.
- The angle at which the axis of rotation of the work piece is shifted is equal to half angle of taper.
- This is done when the body of the tailstock is made to slide on its base towards or away from the
operator by a set over screw
- It is useful for turning very long tapers up to about 5 °

3. List the types of taper turning methods and explain any one with neat sketch.
Taper turning methods.
(i) By setting over the tailstock centre.
(ii) By swiveling the compound rest.
 (iii) By using a taper turning attachment.
(iv) By manipulating the transverse and longitudinal feeds of the slide tool simultaneously.
(v) By using a broad nose form tool.

4. Calculate the time required for one complete cut on a work piece of 60 mm diameter and
400 mm long. The cutting speed is 60 m/min and the feed 0.5 mm/rev.

5. Estimate the time to drill the hole for a length of 40 mm considering the approach and
over travel of 2.6 mm each with a feed of 0.3 mm/rev. At what speed of 30 mm drill will
run for cutting the steel at 30 m/min surface speed.

6. Explain with neat sketch following drilling operations :

(i) Reaming
(ii) Boring
(iii) Counter sinking
Counter Sinking
It is an operation of forming a conical shape at the end of a drilled hole. It is done using a Counter sink
tool.
The cutting speed for this operation must be kept Slow to avoid Chatter.
This Counter sunk hole are used as recess for flat head screw or Counter sink Screw. It is also used for
deburring.
Slandered countersink angle are 60 °, 82 °, 90°
 Unit -2
1. Suggest and explain suitable process for machining 5mm wide and 3mm deep internal
key way in a pulley.
Internal Keyway
A shaper machine can cut Slots for grooves or external keyways on shafts or internal keyways on pulley.
For cutting slots or Keyways a square nose to is selected.
Internal Keyways are cut by holding tool on a special tool holder so that the tool post will not hit against
the work at the end of the stroke.
The clapper box is locked in the clapper box to prevent the tool from lifting during the return stroke.
Lubrication is necessary to prevent the tool wear.

Unit -3
1. Enlist the types of pattern and state the procedure for pattern construction.
1. Solid or Single piece pattern
- Flat face or flat block pattern
- Symmetrical pattern
2. Split piece or Two piece pattern
- Three piece pattern
3. Loose piece pattern
4. Gated pattern
5. Pattern with follow board
6. Match plate pattern
7. Segmental pattern
8. Sweep pattern
Steps of Pattern Construction :
(i) Make a thorough and careful study of the pattern layout and establish
(a) the location of parting surface
(b) the number of parts in which a pattern is to be made.
(ii) Fabricate different parts of the pattern using different hand tools and pattern making machines.
(iii) Join the different parts by glue.
(iv) Inspect the pattern for alignment of different parts and accuracy.
(v) Provide suitable fillets in order to avoid sharp corners.
(vi) Polish the surfaces with sand paper and give three coatings of shellac to make it moisture and
atmospheric attack resistant.
(vii) Impart suitable colors to different portions of the pattern.

Unit -4
1. Differentiate between direct and indirect extrusion. Discuss their relative merits and
demerits.

Direct Extrusion Indirect Extrusion

Advantage: Advantage:
1. Process is relatively fast 1. Force required is less
2. Large variation is possible 2. Less friction
3. Equipment is simple Disadvantage:
Disadvantage: 1. Ram is weak due to hollowness
1. Discard & Surface Impurity are produced 2. Complex equipment

2. Classify closed die forging. Explain any one with neat sketch.
Types of closed die forging
Drop forging
Press forging
Machine forging or upset forging

Drop forging
1. In this process forging is done by hammering a heated bar in Die cavity. This is performed by using a
special type of hammer known as a drop hammer or drop stamp.
2. Dies used for this purpose are made of two equal parts one part is attached to the tup and other is
attached to the anvil block at the bottom.
3. The tup carrying the top part of the die is lifted to a suitable height by a mechanical means and red hot
metal is placed on lower part of the die.
4. Then tup is allowed to fall from that height on these causes severe blow on metal due to the metals
squeezes into the die cavity.

3. State various application of extrusion processes.

Application of Extrusion:
Rods, tubes, Structural shape, Aircraft parts, cans, lead covered cables, various aluminum bracket.

4. Explain with neat sketch any three press forging operations.

1. Up setting or jumping
- Upsetting or jumping or heading is the process through which the cross section of metal piece is increased
with a corresponding reduction in its length.
- When the metal is heated it goes to plastic state and becomes soft, now if pressure is given to it by
hammer, metal will increase its dimension at right angle to the direction of the application of force.

2. Bending
Bending of bars, flats and other similar stock material is usually done in Smithy shop.
These can be done to produce different types of bent shapes such a angles, ovals, circles.
These operations are carried out on the edge of anvil.

Fullering
- It is the operation of reducing the stock between the two ends of bar at the centre so as to increase in its
length.
- To do these the bottom puller is kept on anvil and heated stock is put over it.
- The top fuller is kept over stock and then force is applied on top fuller.
5. Suggest and explain suitable process for large quantity production of round aluminum
alloy rods with uniform cross section.
1. The process of rolling basically consist of passing the hot ingot through two rolls rotating in opposite
direction at a uniform speed.
2. The space between the roles is adjusted to achieve the desired a thickness of the rolled section
3. Due to reduction in space between a roller squeezing of the ingot metal occurs which results in reduction
of cross section area and increase in its length.
4. The decrease in thickness is called as the draft and increase in the Length and width is called as absolute
elongation and absolute spread.
5. As a result of squeezing the grains elongate in a longitude in the direction of Rolling and the velocity of
material at exit is higher than at entry.
6. After crossing the stress zone the grains start refining.

6. Draw neat sketch of following forging methods:

i) Drop Forging ii) Press Forging iii) Upset Forging
7. Explain the press forging.
Press forging
1. This process involves slow squeezing of plastic metal in closed impression die instead of applying
repeated severe blows of hammer.
2. Due to the continuous pressure imparted by the press on material causes the uniform deformation of
metal within die.
3. Usually two types of presses are used in press forging
1. Hydraulic press for heavy work
2. Mechanical press for light work
4. Forging pressure built up from the start to the end of stroke which results in maximum depth of
penetration and improved grain flow.

Unit -5
1. Explain with sketch electron beam welding.
• It is a special type of fusion welding process.
• Heat required for welding is obtained by high velocity of concentrated electron beam.
• Continuously striking high velocity electron on work piece converts kinetic energy into heat
• This heat energy fuse metal and complete weld.
• Electron are negatively charged particle.
• Electrons are accelerated from filament (cathode) to work piece (anode).
• System performs better is vacuum.
• An electromagnetic coil is used to focus electron beam on work piece.

2. Draw neat sketch showing TIG welding process. Explain its working.
1. It is basically an arc welding process in which the arc is struck between a non consumable tungsten
electrode and the base metal.
2. Special type of electrode-holder which holds the electrode, it also have a passage around electrode for
flow of inert gas.
3. It provide the protective shield around the arc.
4. This gaseous shield protects the electrode, molten metal & heated areas of base metal from atmospheric
contamination (Oxidation).
5. The electrode does not melt in this process. Filler metal may be added as per need.
6. Filler metal is fed manually or in a automatic way.
7. The electrode holder is air cooled or water cooled. Mainly Argon & Helium are used as inert gas.

3. Describe the following welding defects with their causes:

i) Porosity ii) Cracks in the weld iii) Slag inclusions

Defect Causes Remedies

Porosity 1. Base metal composition 1. Preheat
variations 2. Maintain proper arc length
2. Hydrogen embrittlement 3. Use low hydrogen electrode
3. shrinkage. 4. Use recommended procedure for baking
& storing electrodes.
5. Clean joint surfaces &
adjacent surfaces

Cracks 1. Poor ductility on base metal. 1. Use joint key pre heating and/or
2. Hardenability. post heating if necessary.
3. Fast arc travel speed. 2. Cool the welded joint slowly.
4. Electrode with high H2 content. 3. Use another sequence for welding.
4. Use weaving motion.

Inclusion 1. Inadequate cleaning of weld 1. Maintain proper current & heat input.
metal between passes 2. Proper cleaning of weld.
2. Rapid rate of welding
3. Too large electrode
4. Improper current
5. Long arcs.