Manufacturing Processes-II

Chapter-1: Manufacturing Processes

  1. What do you mean by Manufacturing Processes?
  2. State importance of manufacturing.
  3. Define manufacturing process.
  4. State classification of manufacturing process.
  5. Discuss the factors which affect the selection of manufacturing process.

Chapter-2: Metal Casting Processes

  1. What is casting process? State advantages and limitation of casting process.
  2. State classification of casting process.
  3. What is pattern?
  4. What are common materials used for pattern making? Discuss their advantages and disadvantages.
  5. Name various factors which are considered for selection of pattern making material.
  6. Explain various types of patterns with field of application of each.
  7. Define pattern allowance. Name various pattern allowances giving purpose of each.
  8. State the advantages and limitations of wood and metal as pattern material.
  9. Explain what a draft allowance is.
  10. Draw neat sketches of the following and explain:  (i) Skeleton pattern  (ii) Loose piece pattern (iii) Sweep pattern   (iv) Match plate pattern
  11. Explain with neat sketch a gated pattern.
  12. Write in brief about : (i) Shrinkage allowance           (ii) Machining allowance
  13. Describe the following pattern material : (i) Plaster of paris        (ii) Wax
  14. Why colour code is given on the pattern ? Explain the different colour code on different surface of a pattern.
  15. Write in brief about   (i) Requirements of pattern material   (ii) Function of a pattern
  16. State essential constituents of mould material.
  17. Discuss about the principal ingredient of moulding sand.
  18. Name various type of moulding sand stating functions of each.
  19. Name important properties of moulding sand and explain the effect of each on casting process.
  20. What are various binders used in moulding sand ? What is their purpose ?
  21. What are various additive material used in moulding sand ? State their name and effect.
  22. Explain following sand test :   (i) Moisture content test           (ii) Grain fineness test   (iii) Clay content test                (iv) Permeability test
  23. Discuss : Grain shape and size of sand
  24. Explain following properties of moulding sand :                                                                                                                (i) Refractoriness         (ii) Permeability(iii) Flowability            (iv) Cohesiveness
  25. State the difference between natural sand and synthetic sand.
  26. What is core ? List main elements of core materials.
  27. Describe the essential characteristics of cores.
  28. Write different functions of core.
  29. Discuss with neat sketch following core : (i) Horizontal core       (ii) Balanced core (iii) Drop core              (iv) Ram-up core (v) Kiss core
  30. Explain core making process.
  31. Describe various properties required in a core sand.
  32. What is chaplet ? State different types of chaplet and their use.
  33. List the hand tools used in preparing mould.
  34. Write function with neat sketch of the following : (i) Sprue pin     (ii) Vent Rod    (iii) Gate cutter
  35. Discuss about mould boxes.
  36. What is Gating System ? State functions of runner and riser.
  37. State different types of gates with functions of each.
  38. Explain the following terms :  (i) Pouring basin          (ii) Runner       (iii) Riser
  39. Write about gating ratio.
  40. Describe : Gating design considerations.
  41. Give general classification of moulding process.
  42. Explain in brief sequence of steps in moulding process.
  43. Discuss : (i) Green sand moulding (ii) Dry sand moulding (iii) Loam sand moulding         (iv) Plaster moulding
  44. Explain C02 moulding process with their advantages and disadvantages.
  45. State advantages and disadvantages of machine moulding over hand moulding.
  46. Name machine moulding processes and give its applications.
  47. List the steps of cleaning of casting after taking out from mould.
  48. Explain working of tumbling mill.
  49. List various techniques of salvage of casting.
  50. What is the difference between permanent mould casting and sand casting.
  51. Describe : Steps of permanent mould casting.
  52. State advantages and disadvantages of permanent mould casting.
  53. State principle of centrifugal casting and explain in brief its working with sketch.
  54. State advantages of centrifugal casting.
  55. State the principle of die-casting and explain its working with sketch.
  56. Describe advantages and disadvantages of die casting process.
  57. Sketch and explain the construction and operation of hot-chamber die-casting machine.
  58. What is meant by die-casting ? Describe various processes used in die-casting.
  59. What is investment casting ? What are the main materials used for making an investment pattern.
  60. List the steps involved in investment casting.
  61. State advantages and disadvantages and uses of investment casting.
  62. Explain various steps of shell moulding process.
  63. Discuss : Sequence of steps of shell moulding process with its advantages and disadvantages.
  64. Explain : Slush casting.
  65. Write a short note on continuous casting.
  66. Describe in brief with sketch the following types of furnaces : (i) Coke fired pit furnace         (ii) Oil fired crusible furnace.
  67. Discuss advantages, disadvantages and use of following furnace : (i) Tilting furnace (ii) Rotary furnace.
  68. Explain working of induction furnace.
  69. Describe with sketch working of rotary furnace.
  70. State the types of furnaces used in foundries and discuss working of direct arc furnace.
  71. Draw sketch of cupola and name different part of it.
  72. Explain the steps involved in cupola operation.
  73. Mark different zone on a sketch of cupola and explain the chemical reaction taking place in each zone.
  74. Name various ingredients fed into cupola.
  75. Define : (i) Blow holes (ii) Cracks                    (iii) Fins (v) Inclusions               (iv) Metal penetration  (vi) Run out.
  76. What are main factors which are responsible for producing defects in casting ?
  77. Explain : Methods used for inspection of casting.
  78. Discuss nondestructive testing methods.
  79. Describe : (i) Magnetic testing (ii) Ultrasonic testing (iii) X-ray test (iv) Penetrant testing.
  80. Discuss vacuum casting process with its advantages.
  81. What is pouring temperature ? What are the parameters affects the pouring temperature ?
  82. Explain in brief : Pouring equipments
  83. Discuss different consideration for design of casting.
  84. State safety precautions to be observed during casting process.

Chapter-3: Metal Joining Processes

  1. Give classification of metal joining processes.
  2. State names of different pressure and non-pressure welding processes.
  3. What is welding ? How welding is classified ?
  4. Define the “Welding process”.
  5. Write the advantages and disadvantages of the welding processes.
  6. State application of welding processes.
  7. Explain the following terms :   (i) Autogeneous welding          (ii) Homogeneous welding  (iii) Heterogeneous welding     (iv) Weldability
  8. What do you understand by gas welding ?
  9. Explain principle of gas welding and give its advantages and disadvantages.
  10. List the equipments used for gas welding. State functions of each.
  11. Draw three types of oxy-acetylene flames showing clearly different zones.
  12. Explain with neat sketch fore hand and back hand gas welding..
  13. Explain with sketch back hand oxy-acetylene welding process with angle of torch and welding rod position.
  14. Give applications of gas welding.
  15. Describe steps of correct gas welding procedure.
  16. Describe the appearance and properties of neutral flame, reducing flame and oxydising flame.
  17. What is the difference in construction of oxygen and acetylene cylinder ?
  18. State safety precautions in gas welding.
  19. State the common defects with their causes in gas welding job.
  20. State advantages and disadvantages of gas welding.
  21. Explain with help of a sketch the construction and working of a gas welding torch.
  22. Write short notes on : (1) Advantages and disadvantages of gas welding       (2) Gas cutting
  23. How the ends for joint prepared ? Explain.
  24. Explain the principle of arc welding. Give its advantages, disadvantages and uses.
  25. Explain in brief : Carbon arc welding.
  26. State precautions to be observed during arc welding.
  27. State the characteristics of TIG.
  28. What are the general safety precautions to be observed in a welding shop.
  29. Discuss the role of welding process in present age.
  30. State the name of equipment used in arc welding. Give functions of each.
  31. State step by step procedure of arc welding.
  32. Why is it important to clean the surfaces to be welded ?
  33. Explain advantages and disadvantages of A.C. and D.C. power used in an arc welding process.
  34. Explain difference between straight polarity and reverse polarity in arc welding.
  35. What are the functions of flux in a metal arc welding ? State names of various materials used as flux.
  36. Write short note on electrodes used in arc welding, state its application.
  37. What is the difference between shielded and unshielded arc-welding processes ? Give schematic representation of shielded metal arc.
  38. State functions of flux used in submerged arc welding.
  39. State names of coating materials used on arc welding electrodes and give functions of coating.
  40. What factors must be considered when selecting a coated welding rod ?
  41. State factors affecting weldability.
  42. Explain : Submerged arc welding.
  43. Stated advantages, disadvantages and uses of submerged arc welding.
  44. Describe with the help of sketch submerged arc welding.
  45. State four advantages of TIG and MIG welding processes over arc welding.
  46. State different advance welding processes and explain any one in brief.
  47. Explain the principle of MIG welding and state its applications.
  48. State applications of submerged arc welding.
  49. Explain the meaning of TIG and MIG welding.
  50. List important qualities of TIG and MIG welding.
  51. State advantages, disadvantages and uses of TIG and MIG welding.
  52. With a neat sketch, explain MIG.
  53. State the salient features of TIG welding.
  54. Write short note on the following :  (1) Metal arc welding               (2) Tungsten inert gas arc welding  (3) Metal inert gas arc welding (4) Submerged arc welding  (5) Plasma arc welding             (6) Thermit welding
  55. What is the principle of resistance welding ? State the formula to find heat required in resistance welding.
  56. State names of methods of resistance welding. Explain any one of it.
  57. Explain the following terms with help of sketches :  (1) Spot welding          (2) Seam welding         (3) Projection welding
  58. Give advantages, disadvantages and applications of resistance welding.
  59. Write short note on the following : (1) Spot welding          (2) Seam welding  (3) Projection welding (4) Upset welding  (5) Flash welding         (6) Percussion welding
  60. Explain the principle of thermit welding.
  61. State method of representing “weld” as per IS : 813 – 1961.
  62. Define the terms related to welding and cutting as per IS : 812 – 1957.
  63. What are the general safety precautions to be observed in welding shop ?
  64. Define soldering process and explain soldering process.
  65. Describe step by step procedure for soldering.
  66. State names of metals used as “solder” and give functions of each.
  67. State fluxes used in soldering.
  68. Give criterion for soldering.
  69. State the applications of soldering.
  70. State difference between soldering and brazing.
  71. Define brazing. How brazing differs from braze welding ?
  72. List the reasons why soldering or brazing is used instead of welding.
  73. Explain with neat sketch the principle of Thermit welding.
  74. Explain with neat sketch the principle of Electron Beam Welding.
  75. Describe briefly the seam welding process.
  76. List the sequence of steps for brazing process.
  77. State filler metals used in brazing giving functions of each.
  78. Why brazing is preferred instead of welding for tool bits ?
  79. Write in brief about methods of brazing.
  80. Explain safety instructions as per IS : 818 – 1968 in arc welding.
  81. Write in brief about defects in weld joint.
  82. Write short notes on the following :  (1) Ultrasonic welding                         (2) Explosive welding  (3) Electron beam welding       (4) Laster welding
  83. What is adhesive joint ? Give its advantages and disadvantages.
  84. State step by step procedure for adhesive joint.
  85. State importance of adhesive joint. State various adhesive materials used for adhesive joint, giving purpose of each.
  86. State any two type of materials used for adhesive joint, giving its use.
  87. List the name of destructive and non-destructive test for weld joint.

Chapter-4: Metal Shaping and Forming

  1. List Advantages and disadvantages of hot rolling processes.
  2. List the various types of rolling mill and explain any one of them.
  3. Distinguish among bloom, billets and slabs as applied to rolling practice.
  4. State the factors causing the defects in cold rolled parts.
  5. Differentiate between hot working and cold working process.
  6. Explain ‘Hot rolling’ with a neat sketch.
  7. Define the terms : (i) Ingot            (ii) Bloom        (iii) Billet         (iv) Slab (v) Strip           (vii) Plate         (vii) Sheet.
  8. List the factors influencing rolling operation and explain any one of them.
  9. State the common defects in cold rolled products and also state the reasons for those defects.
  10. With help of neat sketches explain ‘three high rolling mill’.
  11. List the different metal forming process.
  12. Define ‘metal forming’ process and classify the same by giving one application of each process.
  13. What are the limitations of hot working ?
  14. Explain the method of manufacturing, round bar from a square bloom.
  15. State advantages an disadvantages of cold rolling.
  16. List the various types of rolling mills and explain any one.
  17. Explain four high rolling mill.
  18. List major elements of rolling mil! and write the function of each.
  19. Explain cluster mill with neat sketch.
  20. Explain universal rolling mill with neat sketch.
  21. Explain planetary rolling mill with sketch.
  22. Slate the major difference between ‘Hot rolling process’ and ‘Cold rolling process’.
  23. State the factors influencing the rolling operation and explain the effect of roller diameter.
  24. Describe with help of neat sketch the up set forging operation.
  25. List the correct sequence of forging operations while producing a hexagonal headed bolt.
  26. Write brief note on press forging.
  27. List the defects in a forged parts.
  28. List the different forging operations and describe any two of them.
  29. State the advantages of hot rolling as compared to cold rolling.
  30. Give the classification of forging process and explain ‘Drop forging’ with neat sketch.
  31. State the common defects in forged components stating the reasons for those defects.
  32. Explain ‘Press forging’ process. State the types of press used for the process.
  33. Define forging, differentiate drop forging and press forging.
  34. Name the different methods of forging processes and explain any one.
  35. State the characteristics of forged parts.
  36. State the sequence of operations to produce connecting rod by drop forging.
  37. Explain the points in selection of drop forging.
  38. Explain the factors affecting the drawing operation.
  39. Differentiate between drawing down and deep drawing operation.
  40. Name atleast four components produced by drawing operation and type of drawing process used for each of them.
  41. State the difference between ‘Shallow drawing’ and ‘Deep drawing’ with neat sketches.
  42. Explain wire drawing process with neat sketch.
  43. Explain the process of making chain by forging.
  44. Explain blank drawing with neat sketch.
  45. Explain tube drawing with neat sketch.
  46. Give characteristics of drawing process.
  47. State the applications of drawing process.
  48. List the factors affecting the drawing process.
  49. Differentiate between forward extrusion and backward extrusion
  50. Describe in brief the manufacturing of collapsible tubes by impact extrusion forcess.
  51. Differentiate between ‘Hot extrusion’ and ‘Cold extrusion’.
  52. Explain : (i) Direct or forward extrusion and (ii) Indirect or backward extrusion.
  53. Define extrusion, sketch and explain ‘Indirect extrusion process.’
  54. Explain forward extrusion with the help of neat sketch.
  55. List the methods of extrusion process and explain any one.
  56. Explain side extrusion process.
  57. Write the advantages and limitations of extrusion process.
  58. Explain the principle of extrusion process, name products, produced by extrusion process.
  59. Explain cold or impact extrusion process.
  60. Describe spinning process with a neat sketch.
  61. Define the following terms : (i) Bending       (ii) Embossing              (iii) Stretch forming.
  62. Explain the spinning process. Also suggest the type of lathe most suitable for spinning operation.
  63. Explain ‘Shot peening’ operation and state its purpose.
  64. Describe : (i) shot peening (ii) embossing (iii) stretch forming.
  65. Explain embossing operation with sketch.
  66. Explain bending process and bending allowance.
  67. Explain coining process.
  68. Explain swaging process.
  69. Explain stretch forming process.
  70. State two applications of each of the following process : (i) forging        (ii) rolling         (iii) extrusion.
  71. Write short notes on any two of the hot working process : (i) Rolling        (ii) Spinning     (iii) Drawing
  72. Define the following terms : (i) Spinning      (ii) Bending      (iii) Forging      (iv) Bulging.
  73. Explain the following operations :  (i) Curling operation  (ii) Bulging operation  (iii) Tube forming operation
  74. Explain shearing process.
  75. Explain : piercing and blanking
  76. List the forging operations.
  77. Give classification of types of press.
  78. Give name of different parts of press with their function.
  79. Give neat sketch of mechanical press and label the name of its parts.
  80. Give name of different drive mechanism used in press.
  81. Give name of press according to design of frame.
  82. List the name of operation which are performed on press.
  83. Which points are considered for selection of press ?
  84. Write in short (a) press capacity (b) shut height.
  85. Define following :  (i) Slitting         (ii) Lancing      (iii) Piercing     (iv) Blanking.

Chapter-5: Plastic, Ceramic and Glass Processing

  1. Define the term polymer.
  2. What is polymerization ? Discuss the various methods of polymerization.
  3. What are the different types of plastics and their properties.
  4. What are the characteristics of thermoplastics.
  5. Describe the various additives with their use added in plastics.
  6. Discuss : Classification of plastics.
  7. Write in brief about types of thermosetting resins.
  8. Describe types of thermoplastic resins.
  9. Describe with neat sketches the following plastic processing methods, stating their advantages and applications :  (i) Compression moulding  (ii) Injection moulding  (iii) Blow moulding
  10. What are the advantages of injection moulding over compression moulding process of plastic ?
  11. Sketch and explain :   (1) Transfer moulding  (2) Extrusion moulding
  12. Sketch and explain calendering process of plastics.
  13. What are laminated plastics ? State their characteristics and use.
  14. Explain the difference between high pressure and low pressure plastic laminating process.
  15. What is rotational moulding of plastics ?
  16. Explain : Thermoforming process of plastics.
  17. What special cares are taken when machining plastics ?
  18. What are the methods used for joining of plastics ?
  19. Discuss the various design factors for plastic parts.
  20. State the basic material used to produce ceramics.
  21. Give classification of ceramics.
  22. Explain various ceramic structures.
  23. Explain characteristics of silicate ceramics.
  24. Write in brief about ceramic properties.
  25. State different application of ceramics.
  26. Explain glass structure.
  27. Discuss properties of glass.
  28. State classification of composite materials.
  29. Explain : (1) Metal matrix composites  (2) Ceramic matrix composites
  30. Write in brief about surface coated materials.
  31. Describe glass fibre reinforced plastics.
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