MANUFACTURING PROCESS I (ME204) QUESTION BANK Chapter - ! C"#$ept% "& Ma#'&a$t'r(#) 1. 2. 3. 4. 5. 6. 7. ". &. 1'. 11. 12.

. What is a process? What are the general categories of manufacturing? What is process planning? What are the functions of a process engineer? Enumerate the principle types of manufacturing. Classify the different types of manufacturing processes. o! is right type of manufacturing process selected? #ist and e$plain the different methods of analy%ing a manufacturing system. Enumerate the types of production processes. #ist the acti(ities and operations in(ol(ed in manufacturing. What are the processes of process planning? E$plain )riefly the follo!ing types of production* +a, -o) order production +c, 0ass 1roduction. Chapter -2! Ca%t(#) Pr"$e%% 1. 2. 3. 4. 5. 6. 7. ". &. 1'. 11. 2efine the terms 3Casting4 and 35oundry4. Why casting is preferred o(er other methods of manufacturing? 2iscuss. What are the common )asic features to (arious casting process. What is a pattern? What are the )asic features common to (arious casting processes? 2iscuss their relati(e merits and demerits. What considerations are necessary !hile designing a pattern? o! is layout of a pattern made? 6tate the procedure for pattern construction. 2iscuss )riefly (arious types of pattern materials. #ist the types of factors on !hich the (arious types of patterns depend. Enumerate the (arious types of commonly used patterns. With neat s7etches e$plain )riefly solid pattern8 s7eleton pattern and loose piece pattern. +), .atch or /uality production

12.

With neat s7etches e$plain )riefly the follo!ing patterns* +a, 6egmental pattern +), Cope and drag pattern pattern. +c, 6!eep

13. 14.

#ist the (arious types of allo!ances !hich are usually pro(ided in a pattern. E$plain )riefly the follo!ing pattern allo!ances* +a, 6hrin7age allo!ance +c, 9apping or sha7ing allo!ance +), 0achining allo!ance +d, 2istortion allo!ance

Chapter -*! M"'+, Ma-(#) 1. 2. 3. 4. 5. 6. 7. ". &. 1'. 11. 12. 13. 14. 15. 16. 17. What are the main characteristics !hich a good moulding sand should posses? o! does the characteristics of moulding sand influence the performance during moulding and casting? 2iscuss )riefly the materials !hich are added to moulding sand to impro(e their moulding properties. E$plain ho! the grain si%e and shape affect the performance of foundry sand. 2iscuss )riefly the influence of !ater:content on moulding sand properties. E$plain the process of sand preparation and sand conditioning. What is 36top:off4? E$plain )riefly. E$plain )riefly8 parting sand8 facing sand and )ac7ing sand. What are mould surface coatings? E$plain. E$plain the process of sand preparation and sand conditioning. Why testing of foundry sand is necessary? What are the common tests performed on foundry sands? What are the main characteristics of a good core sand? What are the main core )inders? 2iscuss their uses in ma7ing core sand. Classify the different types of moulds and state their ad(antages. 2ra! the s7etch of a typical mould and name its principal parts. What is stac7 moulding? 67etch and descri)e the follo!ing techni/ues8 stating clearly their ad(antages and special applications * +a, use of false cope8 +), use of dry sand cores8 +c, use of dra!)ac7s8 +d, )edding:in8 +e, coping do!n. 1". o! does machine moulding differ from hand moulding? #ist the ad(antages and disad(antages of moulding machines. 1&. 2iscuss )riefly moulding machines.

2'. 6tate the ad(antages of the follo!ing +a, 2ry sand mould o(er green sand mould8 +), #oam mould o(er dry sand mould8 +c, 1ermanent mould o(er dry sand mould. 21. With a neat s7etch e$plain )riefly the construction and !or7ing of a cupola furnace. 22. With a neat s7etch e$plain )riefly the electric furnace. Chapter -4! Gat(#) S.%te/% 1. 2. 3. 4. 5. 6. 7. ". What is a gate and list the functions of a gating system. With a neat s7etch e$plain the different parts of a gating system. o! a gate is designed? What is meant )y 3risering4? 6tate the ad(antages that are pro(ided )y a riser. What is the )est shape and si%e of a riser? Why? Write short notes on +a, ;se of padding +), ;se of e$othermic materials8 and With neat s7etches e$plain the different types of gating systems. What is gating ratio? E$plain. Chapter -0! C""+(#) a#, S"+(,(&($at("# 1. 2. 3. 4. 5. E$plain )riefly the process of crystalli%ation of pure metals. What is dendritic solidification? E$plain. What is the critical si%e of nucleation that nucleates from melt? 2educe the e$pression for free energy concept in solidification. E$plain the follo!ing* +a, <ormal segregation8 +c, 0icro:segregation and 6. +), =ra(ity segregation8 +d, 0acro:segregation.

What is the scope of chills in o)taining directional solidification? E$plain. Chapter -1! Ca%t(#) Pr"$e%%e%

1. 2. 3.

What are the steps in(ol(ed in preparation of a casting? 6tate the ad(antages and disad(antages of casting process. What are the )asic rules for good casting design?

4. 5. 6.

#ist the different types of casting processes. With a neat s7etch e$plain the sand casting process. Write short notes on* +a, 6hell:mould casting8 +), 1laster:mould casting8 Ceramic:mould casting8 +d, >acuum casting and E(aporati(e pattern casting. +c, +e,

7. ". &.

With neat s7etch?s e$plain the in(estment casting process. #ist its ad(antages8 disad(antages and applications. E$plain )riefly slush casting8 electroslag casting8 precision casting8 semi solid metal forming and pressed casting. What is centrifugal casting? 5or !hat type of @o)s !ould you recommend this casting process?

1'. E$plain )riefly true centrifugal casting8 semi:centrifugal casting and centrifugal casting. 11. What is continuous casting? E$plain the process of continuous casting !ith a neat s7etch. 12. #ist the ad(antages claimed )y permanent mould casting o(er sand casting. 13. 2escri)e the pre:design consideration in the design of castings. 14. #ist the factors !hich influence the choice of the proper casting method. 15. Enumerate the methods of repairing and sal(aging defecti(e castings. 16. What are the common defects of casting? 6tate their causes and remedies. 17. E$plain )riefly the different types of cleaning operations performed on castings. 1". 2iscuss )riefly the (arious methods employed to inspect the castings. Chapter -2! 3"t 4"r-(#) pr"$e%%e% F"r)(#) 1. 2. 3. 4. What do you understand )y the term forging? o! does hand forging differ from machine forging? 6tate the ad(antages and disad(antages of forging. E$plain )riefly the follo!ing three )asic categories of forging* +a, Apen:die forging8 +), Bmpression:2ie forging8 and Closed:die forging. 5. 6. 7. ". &. What are the different operations carried out )y hand forging? E$plain. What are the different types of machines used in machine forging? E$plain. What is forgea)ility? E$plain. E$plain )riefly the follo!ing forging processes* +a, 1recision forging and +), Bsothermal forging. E$plain )riefly (arious cold forging techni/ues. +c,

1'. What do you understand )y the term draft on forgings and !hy is it pro(ided? 11. 2escri)e )riefly the follo!ing forging processes* +a, 2rop forging8 +), 1ress forging8 and +c, 0achine forging. 12. E$plain )riefly the follo!ing types of forging processes* +a, 9oll forging8 +), 9otary forging or s!aging8 +c, igh (elocity forging8 +d,Ar)ital forging8 +e, Bncremental forging8 +f, #i/uid metal forging8 and +g, =atori%ing. 13. E$plain )riefly the (arious defects in forging. 14. o! are forgings cleaned and finished? E$plain )riefly. Chapter -5! 6e+,(#) a#, A++(e, pr"$e%%e%! 1. 2. 3. 4. 5. 2efine the term !elding and name the (arious !elding techni/ues. #ist out the ad(antages8 disad(antages and applications of !elding. E$plain forge !elding !ith their ad(antages and disad(antages. What is the principle of operation of resistance electric !elding? E$plain the follo!ing resistance electric !elding processes* +a, .utt !elding8 +), 5lash !elding8 +c, spot !elding8 !elding8 +e, 1ro@ection !elding8 and +f, 1ercussion !elding. 6. 7. ". &. +d, 6eam

What do you understand )y gas !elding? #ist its ad(antages8 disad(antages and applications. 2escri)e in )rief the e/uipment re/uired for o$y:acetylene gas !elding. What are the different types of flames o)tained in gas !elding? E$plain. E$plain the left!ard and right!ard methods of gas !elding.

1'. With a neat s7etch e$plain o$y:acetylene gas !elding. 11. 2efine soldering. <ame types of solders. 12. E$plain )riefly the term C5lu$4 or C6oldering fluid?. Enumerate the flu$es commonly used in soldering process. 13. 2escri)e )riefly the e/uipments used in soldering. 14. o! is soldering process carried out? 15. What are the characteristics of a good soldering @oint? 16. 6tate the applications of soldering. 17. E$plain the term C.ra%ing?. 1". What is the action of a flu$ in )ra%ing process? <ame the chief flu$ used in )ra%ing. 1&. 2escri)e step !ise the procedure of )ra%ing. 2'. Enumerate the applications of )ra%ing. 21. What are the characteristics of a good !eld?

22. E$plain the different defects in !elds. 23. 2efine !elda)ility. What factors affect !elda)ility e$plain. 24. #ist the different tests carried out in inspecting the !elded @oints. 25. What are the )asic principles of !elding design? Chapter -7! E+e$tr($ Ar$ 6e+,(#) 1. 2. What do you understand )y electric arc !elding? #ist its ad(antages and disad(antages. With neat s7etches e$plain in )rief the follo!ing electric arc !elding processes* + a, 0etallic arc !elding8 3. 4. 5. 6. 7. ". &. +), Car)on arc !elding8 +c, Dtomic arc !elding8 and +d, 6hielded arc !elding. What do you mean )y arc )lo!? E$plain. o! do you compare DC and 2C for arc !elding? What are the ad(antages of each of the se(eral sources of current for arc !elding? What do you understand )y the term Cpolarity? and !hat is the ad(antage and disad(antage of ha(ing different polarity. What are the different types of electrodes used in electric arc !elding? E$plain. What are the functions of coatings on shielded electric arc electrodes? With neat s7etches e$plain the different types of !elding @oints.

1'. With neat s7etches e$plain the different types of !elding positions. Chapter - 0! Spe$(a+ 6e+,(#) Pr"$e%%e% 1. 2. 3. 4. 67etch and e$plain Ehermit !elding process. #ist its ad(antages8 limitation and applications. With neat s7etches e$plain EB= and 0B= !elding processes. Dlso gi(e their ad(antages8 limitations and applications. 2ifferentiate )et!een EB= and 0B= !elding processes. E$plain the follo!ing !elding processes gi(ing neat s7etches* +a, 6u)merged arc !elding8 +), +c, Electro:gas !elding. 5. 6. 7. ". 67etch and e$plain the electron )eam !elding process. With a neat s7etch e$plain the ultrasonic !elding process. 67etch and e$plain plasma arc !elding process. =i(ing the ad(antages and limitations e$plain the laser )eam !elding process !ith a neat s7etch. Electro:slag !elding8

&.

E$plain the follo!ing non traditional !elding processes* +a, 5riction !elding8 +), E$plosi(e !elding8 +c, 2iffusion !elding8 +d, Bnduction !elding8 +e, Bnduction !elding8 +f, Cold !elding8 +g, 6tud:arc !elding8 +h, ydrodynamic !elding8 and +h, under !ater !elding