Roll Number: _______________________________________________________

Thapar Institute of Engineering & Technology, Patiala

Department of Mechanical Engineering
End Semester Examination (EST)
Subject Name: Manufacturing Processes Subject Code: UES102

Date: 18th Dec. 2024 Name of Faculty: Prof. Vivek Jain, Prof. Dheeraj Gupta, Dr. R.S.Joshi,
Time: 9:00 hrs-12:00 hrs Duration: 3 Hours Dr. Ratnesh Kumar Raj Singh, Dr. Arshpreet Singh, Dr. Sachin Singh,
Max Marks: 75 Weightage: 40 Dr. P Kalyan Chakravarthy

Note: (1) Attempt any three questions; all questions have equal marks (2) Mark the number of attempted questions and its page
number at front page of answer sheet. Write ‘NA’ for ‘Not-Attempted’ question at front page of answer sheet. (3) If any student
attempt more than 3 questions then only first 3 questions will be evaluated (4) All sub-sections of the respective question should
be attempted at one place. (5) Mention your group number on the top of the answer sheet. (6) Support your answers with neat sketches
wherever required. (7) Assume suitable missing data, if any.

M.M CLO/
BL

Q 1 (a) A manufacturing industry plans to cast a steel rectangular plate with dimensions of 100 mm × 150 mm 10 3/L3
× 30 mm, intended for a critical machinery component. To ensure defect-free casting, a cylindrical side
riser is to be designed. The riser’s height is specified to be twice its diameter. The total solidification
time for the plate is 3 minutes, and Chvorinov’s rule (with an exponent of 2) governs the solidification
process. Determine the minimum diameter of the riser (in mm) which satisfies the use of a riser.

(b) Why is it important to minimize turbulence in molten metal flow? Discuss the various strategies 5 3/L4
employed in designing a gating system to reduce turbulence. Illustrate your explanation with schematic
diagrams.
 Turbulent flow is generated while pouring the molten metal into the mold which causes the following problems:–
absorption of gases,

– oxidation of the metal, and

–erosion of the mold. (2)

Short sprues are desirable, since they minimize the distance that metal falls when entering to the mold and kinetic
energy acquires during that fall.
Rectangular pouring cups prevent the formation of a vortex or spiralling funnel, which tends to suck gas and
oxides into the sprue
Tapered sprues also prevent vortex formation

A large sprue well can be used to dissipate the kinetic energy of the falling stream and prevent splashing and
turbulence as the metal makes the turn into the runner. (2+1
schematic)
(c) Enumerate the different types of allowances provided in patterns. Explain any one positive and negative 5 3/L2
allowance with a schematic.
1. Shrinkage or contraction allowance
2. Machining or finish allowance
3. Draft or taper allowance
4. Distortion or camber allowance
5. Rapping allowance (2)
solid state contraction is taken care by the pattern makers by giving a positive shrinkage allowance.

or

Machining allowance is a positive allowance given to compensate for the amount of material that is lost
in machining or finishing the casting.

or

Draft is the taper provided by the pattern maker on all vertical surfaces of the pattern so that it can be
removed from the sand without tearing away the sides of the sand mold.

Before withdrawing the pattern it is rapped and thereby the size of the mould cavity increases. This
allowance is kept negative and hence the pattern is made slightly smaller in dimensions.
(1.5+1.5 each with schematic)

(d) Compare in a tabular form, the different types of die casting processes in terms of (i) Injection pressure 5 3/L4
(ii) production rate (iii) cycling time (iv) usage of the process.
How can liquid phase shrinkage be compensated and air entrapment avoided in the die casting process?

Hot chamber die Cold chamber die

casting casting

Injection low (7-35 MPa) High (14-140

pressure MPa)

production rate 100 shots per min Low

(high)

cycling time Faster Low

 usage of the low melting point High melting point
process alloys (zinc, tin, alloys (Al, brss,
lead) Mg)

(3)
Risers are not used in the die-casting process since the high injection pressures ensure the continuous feed of
molten metal from the gating system into the casting.

venting holes and passageways must be built into the dies at the parting line to evacuate the air and gases in the
cavity. (2)
Q 2 (a) The arc voltage characteristics of a DC welding power source is given by V=20+40L volts (L is in cm). 10 4/L3
During a welding operation the arc length (L) is expected to vary between 4 and 6 mm with the welding
current limited between 450 and 550 amperes. During the constant voltage power source, calculate the
arc power at an arc length of 5 mm.
Solution:

(b) Identify and draw the schematics of specific welding processes where low voltage (V) and high current 5 4/L4
(kA) are used in the following cases:
(a) Dimples are embossed onto one of the workpieces.
(b) Continuous joining of overlapping sheets.
(c) Joining two or more overlapped metal sheets.
Solution: Resistance Welding (01 Marks)
 (Figure: 01 Marks)
(a) Projection Welding (01 Marks) (b) Seam Welding (01 Marks) © Spot Welding (01 Marks)

(c) A medical research institute is exploring advanced techniques to create customized prosthetic limbs of 5 5/L2
polymers. The institute is seeking a 3D printing technology that can provide rapid prototyping,
customization, and affordable production for patient-specific applications. Schematically explain the
wire-based 3D printing technology for creating customized prosthetic limbs for patients.

ANS: Fuse deposition modelling (FDM) (01 Marks)

Material is drawn through a nozzle, where it is heated and is then deposited layer by layer First layer is built
as nozzle deposits material where required onto the cross sectional area. The following layers are added on
top of previous layers. Layers are fused together upon deposition as the material is in a melted state. (02
Marks)

(02 Marks FOR FIGURES ANY ONE)

(d) Why a cutting tool with a negative rake angle of -10° is used to machine a hard & brittle alloy workpiece 5 1/L4
during turning operation? Compare the cutting forces and surface finish in a tabular form, when
machining the same workpiece with tools of -10° and +10° rake angles.
Solution: The workpiece material has high strength and hardness due to which it is requiring increased tool
strength. (02 Marks)
The cutting forces are measured to be higher compared to using a tool with a positive rake angle.
(1.5 Marks)

The machined surface shows an improved finish due to the compressive forces generated by the negative
rake angle. (1.5 Marks)

Q 3 (a) Spot welding of two 1 mm thick sheets of steel (density = 8000 kg/mm3) is carried out successfully by 10 4/L3
passing a certain amount of current for 0.1 seconds through the electrodes. The resultant cylindrical weld
nugget formed is 5 mm in diameter and 1.5 mm thick. If the latent heat of fusion of steel is 1400 kJ/kg
and the effective resistance in the welding operation is 200 μΩ, what is the current passing through the
electrodes?
Solution:
Given data:
thickness of sheet (t) = 1 mm
Density of Steel = 8000 kg/mm3
time (t1) = 0.1s
diameter of the nugget is (dn) = 5 mm
thickness of the nugget is (tn) = 1.5 mm
Latent heat of fusion of steel = 1400 kJ/kg
Resistance (R) = 200 μΩ
(b) A series of cold rolling operations are to be used to reduce the thickness of a plate from 100 mm down to 5 2/L3
85 mm. Roll diameter = 400 mm and coefficient of friction between rolls and work = 0.15. The
specification is that the draft is to be equal on each pass. Determine: (a) minimum number of passes; and
(b) draft for each pass.
Given:
to = 100 mm, tf =85 mm,
Roll diameter = 400 mm, therefore R = 200 mm
μ = 0.15
Maximum draft dmax = μ2 R = 4.5 mm (2 marks)
Minimum no. of passes = (t0 – tf)/dmax = 3.33 = 4 passes (2 marks)
Draft per pass = (100 - 85)/4 = 3.75 mm (1 marks)

(c) An arc welding process with a non-consumable electrode is employed for precision welding of critical 5 4/L2
components in a nuclear plant. Justify this statement by explaining the process in detail with a neat
illustration.
The welding process with a non-consumable electrode is employed for precision welding of critical
components in a nuclear plant is Tungsten inert gas (TIG) welding. (1 marks)

The heat for Gas Tungsten Arc Welding (GTAW) is produced by an electric arc maintained between
a non-consumable tungsten electrode and the part to be welded.
The heat-affected zone, the molten metal, and the tungsten electrode are all shielded from the
atmosphere by a blanket of inert gas fed through the GTAW torch.
Inert gas is that which is inactive, or deficient in active chemical properties.
It does not burn, and adds nothing to or takes anything from the metal.
Inert gases such as argon and helium do not chemically react or combine with other gases.
The torch holding the tungsten electrode is connected to a shielding gas cylinder as well as one
terminal of the power source.
The tungsten electrode is usually in contact with a water-cooled copper tube, called the contact tube,
which is connected to the welding cable (cable 1) from the terminal.
The workpiece is connected to the other terminal of the power source through a different cable (cable
2). (2 marks)

(2 marks)
 (d) Listed below are the common defects that may occur in sand castings. Complete the table 1 by specifying 5 3/L2
their category and including the corresponding schematic representation of each defect.
Table 1

Sr. No. Defect Category Schematic

1 Mis-run Pouring metal defects

2 Cut and Washes Molding material

defects

3 Open holes Gas defects

4 Hot tears Metallurgical defects

5 Shrinkage Shrinkage defects

cavity

Each carry 1 mark (0.5+0.5)

Q 4 (a) Write a CNC program for engraving the dotted profile (as shown in Fig. 1) (ABCDEDFGHIJKLA) in 15 1/L3
absolute mode. Use the following data:
● Depth of profile is 3 mm.
● The diameter of the cutter is 3 mm, and the height is 15 mm.
● Cutting speed and feed rate are 0.50 m/s and 100 mm/min.
 Fig.1.

5 5/L2

(b)
(c) What are the end effectors of a robot? What type of end effector will be suggested in the robot if it is used
for (a) picking large glass sheets (b) picking ferrous material (c) performing spot welding
Definition of end effector: The special tooling for a robot that enables it to perform a specific task. it
is used for grasping, drilling, painting, welding, etc. (2 marks)
(a) picking large glass sheets :Pneumatic/ suction cups (1 marks)
(b) picking ferrous material : Magnetic (1 marks)
(c) performing spot welding : Welding gun/torch (1 marks)

(d) Draw a detailed stress-strain curve for the material preferred for forming processes and also mark the zone 5 2/L3
in which forming operations are to be carried out.
 ------(2 for only graph +1 for
labeling yield point and ultimate point) Marks
After yield point to upto ultimate strength—-2 marks

Hand Out: CNC Milling G95 – Feed in mm/rev

G01 X_ Y_Z_F_– Linear motion with feed X – Absolute mode in X- axis
G02 X_ Y_Z_R_– Tool movement in clockwise direction Y – Absolute mode in Y- axis
G03 X_ Y_ Z_R_– Tool movement in anti-clockwise direction Z - Absolute mode in Z- axis
G20 – Inches mode M03 – Spindle rotation clockwise
G21 – Metric mode (in mm) M04 – Spindle rotation anti-clockwise
G28 – Go to machine home position in incremental mode M05 – Spindle stop
G43H1 – Height offset of the tool in downward direction M06 – Tool change
G90 – Absolute method M30 - Program Stop and Rewind.
G91 – Incremental method M98 – Sub program calling
G94 – Feed in mm/min M99 – Sub program end