Manufacturing Processes-I

Question Bank

Unit-I
Introduction to Overview of Manufacturing

Six marks Questions

Q.1. How do you classify the manufacturing processes?

Q.2. Distinguish between ‘primary’ and ‘secondary’ processes?
Q.3. Explain the term ‘Manufacturing System’. What all it encompasses and how an
integrated approach is made for making an economical and competitive product?
Q.4. Define technology and manufacturing.
 Manufacturing Processes-I

Question Bank

Unit-II
Solidification Processes Metal Casting Fundamental

Q.1. Four Marks Questions

1. Define casting. What four basic steps are generally involved in making a casting?
2. What are the common factors which should be considered before designing a
casting?
3. Explain briefly the main constituents of molding sand.
4. How do the grain size and shape affect the performance of molding sand?
5. How natural molding sands differ from synthetic sands? Name major sources of
obtaining natural molding sands in India?
6. How are binders classified?
7. Describe the process of molding sand preparation and conditioning.
8. Name and describe the different properties of good molding sand.
9. What are the common tests performed on molding sands?
10. Name and describe briefly the different additives commonly added to the molding
sand for improving the properties of the molding sand.
11. What are the major functions of additives in molding sands?
12. What important factors are considered during melting?
13. What are the factors which govern the selection of a suitable type of furnace for
melting a particular metal?
14. Where skeleton patterns are used and what is the advantage?
15. Where skeleton patterns are used and what is the advantage?
16. Define pattern? What is the difference between pattern and casting?
17. What are the factors which govern the selection of a proper material for pattern-
making?
18. What are the allowances provided to the patterns?
19. Sketch and describe the use and advantages of a gated pattern?
20. Discuss briefly the various functions of a pattern?
21. Write the color coding for patterns and core boxes?
22. What is chill? Explain in brief its uses.
23. Discuss briefly the various types of molds.
24. What are the main requirements expected of an ideal gating system?
25. What is meant by the term ‘risering’?
26. Discuss the common objectives of risers.
27. What advantages are provided by a riser?
28. What is the best shape of a riser, and why?
29. Why is cylindrical shape risers most commonly used?
30. What are the advantages of blind riser over conventional type riser?
31. What is a core? What purposes are served by cores?
32. What are the characteristics of a good core?
 Manufacturing Processes-I

Question Bank

33. Classify the types of cores? Explain them with the help of sketches specifying their
common applications.
34. What is a core binder?
35. What is core print?
36. Describe different types of core sand.
37. Describe hand core making and machine core making.
38. What is “directional solidification”, and what is its influence on casting quality?
39. What are the general advantages, disadvantages applications of die casting?
40. Explain the various steps involved in the investment casting of metals.
41. What do you understand from centrifugal casting?
42. How are the centrifugal casting methods classified?
43. What are the advantages and disadvantages of true centrifugal casting?
26. What are the main factors which are responsible for producing defects in the
castings?
44. What are the common methods used for cleaning the surface of the casting?

Q.2. Six Marks Questions

1. What is Pattern? How does it differ from the actual product to be made from it?
2. What important considerations a pattern-maker has to make before planning a
pattern?
3. What are the common allowances provided on patterns and why?
4. What are master patterns? How does their size differ from other patterns? Explain.
5. Discuss the various positive and negative allowances provided to the patterns.
6. Discuss briefly the match plate pattern with the help of suitable sketch. ?
7. Sketch a blast furnace. Describe its construction and working.
8. How will you specify a cupola furnace?
9. What necessary precautions are required in operating the cupola?
10. What are crucible furnaces? Where are they preferred and why?
11. What are the different types of electric furnaces? Describe anyone of them.
12. Describe crucible furnaces.
13. Write short notes on the following:
(a) Open-hearth furnace and (b) Resistance furnace.
14. Describe the construction working and uses of core less type induction furnace.
15. Give common materials used for pattern making? Discuss their merits and demerits?
16. Classify and discuss the various types of molding sand. What are the main factors
which influence the selection of particular molding sand for a specific use?
17. What is meant by green strength and dry strength as applied to a molding sand?
18. What is grain fineness number? Explain how you will use a sieve shaker for
determining the grain fineness of foundry sand.
19. What is meant by green strength and dry strength as applied to a molding sand?
20. How will you test the moisture content and clay content in molding sand?
21. Differentiate between the process of green sand molding and dry sand molding.
22. Sketch a complete mold and indicate on it the various terms related to it and their
functions.
23. Explain the procedure of making a mold using a split pattern.
24. Write short notes of the following:
 Manufacturing Processes-I

Question Bank

(i) Floor molding (v) Loam molding.

(ii) Pit molding (vi) Plaster molding.
(iii) Bench molding (vii) Metallic molding.
(iv) Machine molding

25. Describe the following:

(i) Skin dried molds (iii) CO2 molds
(ii) Air dried molds (iv) Plaster molds.
27. What do you understand by the term gating system?
28. What are chaplets and why are they used?
29. Using neat sketches, describe various types of chaplets.
30. What are different types of gates? Explain them with the help of sketches stating the
relative merits and demerits of each.
31. Describe the CO2–gas molding process in detail using suitable sketches and stat its
advantages, disadvantages and applications.
32. Name the different steps in core-making? Describe the operation of making a dry
sand core?
33. Describe in detail the terms ‘solid zone’, ‘mushy zone’ and ‘liquid zone’ used in
solidification of castings. Using figures explain the term directional solidification used
in castings.
34. Is directional solidification is necessary in casting? How does it help in the production
of sound castings?
35. What are the controlling factors of directional solidification in casting? Name
different stages through which the metal contraction takes place during the
solidification of the casting?
36. Sketch the cross-section through a permanent mold, incorporating all its principal
parts. Describe its construction in detail.
37. Describe the permanent mold casting process and discuss how it differs from the
other casting processes.
38. Describe step by step procedure for casting using a permanent mold. What are the
advantages, disadvantages and applications of permanent mold casting?
39. What is the difference between gravity die casting and pressure die casting?
40. How are die casting machines classified? What are the common constructional
features embodied in most of them?
41. Sketch and explain the construction and operation of a hot chamber die casting
machine.
42. How does a cold chamber die casting machine differ from a hot chamber machine?
Explain the working of a cold chamber machine with the help of a diagram.
43. What is a vacuum die-casting machine? How is the vacuum applied to hot and cold
chamber machines to evacuate the entrapped air completely. What is the main
advantage of this type of machine?
44. What is investment casting? What are the main materials used for making the
investment pattern?
45. Describe the complete step by step procedure of investment casting. What are the
main advantages and disadvantages of investment casting?
46. Describe briefly the shell casting process using neat sketches. State its advantages,
disadvantages and generation applications.
 Manufacturing Processes-I

Question Bank

47. Describe continuous casting process and discuss the important metallurgical features
of the billets produced by these methods.
48. Explain with the help of a neat sketch, the process of centrifugal casting.
49. With the help of a neat diagram describe the process of true centrifugal casting. How
can this method be used for production of pipes?
50. Illustrate and describe the process of semi-centrifugal casting.
51. Write short notes on the following:
(i) Slush casting (iv) Moore sand spun process
(ii) Pressed casting for centrifugal casting.
(iii) De Lavaud process for
centrifugal casting
52. What is centrifuging casting?. Describe the process, stating its differences with other
centrifugal casting methods.
53. What are the general rules and principles to be followed in designing a casting?
54. List the defects generally occurring from the following, stating the precautions
necessary to prevent them:
(i) Improper pouring (iii) Poor or defective cores,
technique, (iv) High moisture content in
(ii) Use of defective gating sand.
system
55. Write short notes on the following casting defects:
(i) Sand inclusions, (v) Metal penetration,
(ii) Cuts and washes, (vi) Drops,
(iii) Misrun and cold shuts, (vii) Warpage and
(iv) Honey combing, (viii) blow holes
56. Discuss briefly the causes and remedies of the following casting defects:
(i) Blow holes, (iv) Shrinkage cavities,
(ii) Porosity, (v) Scabs, and
(iii) Hot tears (vi) Gas porosity
57. Explain the causes and remedies of the following casting defects:
(i) Fins (vi) Rattails or buckles
(ii) Shot metal (vii) Fusion
(iii) Shifts (viii) Swells
(iv) Hard spots (ix) Crushes
(v) Run out
58. Name the various defects which occur in sand castings and state their probable
causes and remedies?
59. What are the various operations generally required to be performed after shake out
for cleaning the castings?
60. What do you understand from destructive and non-destructive testing methods of
inspecting castings?
61. What are the various non-destructive testing methods used for inspection of
castings? State their advantages and limitations:
62. Write short notes on the following inspection methods:
(i) Visual inspection (iv) Radiography
(ii) Pressure test (v) Magnetic particle testing
(iii) Penetrate testing (vi) Ultrasonic testing.
 Manufacturing Processes-I

Question Bank

Q.3. Eight Marks Questions

1. Make a neat sketch of a cupola, indicating its various zones and describe the
following:

i) Construction iv) Different zones and their

ii) Preparation before functions
operations v) Operation
iii) Charging method vi) Advantages
vii) Limitations and
viii) Application.

2. Explain with the help of neat sketches the construction and working of the following
types of crucible furnaces: (a) A coal fired pit furnace, (b) an oil fired tilting furnace,
and (c) A gas fired crucible furnace.
3. Discus briefly the various types of patterns used in foundry shop?
4. Define the following?
(i) Core prints (iv) Shrinkage allowance
(ii) Mould or cavity (v) Chaplets
(iii) Core boxes (vi) Chills
5. Describe the process of shell molding indicating:
(i) Composition of sand (iii) Advantages
mixture (iv) Limitations and
(ii) Steps in molding (v) Applications.
6. What is the function of the core in sand molding? How are cores held in place in
mold? And how are they supported?
7. Explain the difference with the help of sketches between true centrifugal casting,
semi centrifugal casting and centrifuge casting.
 Manufacturing Processes-I

Question Bank

Unit -III
Metal Forming Processes

1. Define re-crystalline temperature.

2. Differentiate between hot and cold working.
3. Define hot working of metals. What are its advantages and disadvantages?
4. Describe with sketches the three methods of hot working.
5. Explain briefly the various methods of hot extrusion with neat sketches.
6. What is hot extrusion? In how many ways it can be performed?
7. Describe briefly with neat sketches all the process of extrusions.
8. Discuss their relative merits and demerits of different kind of extrusion.
9. How welded pipes and tubes are manufactured?
10. Describe the process of hot extrusion of tubes.
11. Write Short notes on:
a) Hot spinning
b) Hot Extrusion
c) Hot forging
d) Hot drawing.
12. What is roll piercing? And for what purpose is it used?
13. Explain hot rolling and various type of rolling mills used in hot rolling.
14. Write short notes on the following:
a) Hot piercing
b) Hot forging
c) Forging
15. How and why are directional properties obtained in a forged component? Discuss
their advantages, disadvantages and applications.
16. What are the advantages of hot extrusion over rolling and forging?
17. With the aid of a sketch, briefly describe the process of spinning. Why is it called a
flow turning process?
18. Define cold working of metals. What are its advantages and disadvantages?
19. What are the specific advantages, limitations and applications of cold working?
20. Explain the various cold drawing processes.
21. Using neat sketches explain briefly the process of wire-drawing.
22. Describe the process of cold spinning stating its advantages and specific uses.
23. Explain briefly the stretch forming operation.
24. Write short notes on the cold rolling and cold extrusion.
25. Explain the following cold working processes:
a) Cold rolling
b) Stretch forming
c) Cold bending.
26. What is cold forging and swaging?
27. Describe the following cold working processes:
a) Embossing
b) Coining
c) Roll forming
d) Roll bending
e) Shot peening
 Manufacturing Processes-I

Question Bank

28. What is impact extrusion? Explain this process and state its specific applications.
29. Discuss the methods used for the production of pipes and tubes.
30. Using neat sketch describe briefly the method of extruding a hollow round
collapsible tube with help of drawing process.
 Manufacturing Processes-I

Question Bank

UNIT-IV
Joining and Assembly Processes

1. What is welding? How is it classified?

2. What are the advantages, disadvantages and applications of welding joints over
other joints?
3. Explain the various types of joints commonly used in welding.
4. Explain the different kinds of welding positions with neat sketch.
5. Using neat sketch show the various standard location of elements of a welding
symbol.
6. Classify the various welding processes in detail. Describe each in brief.
7. What effect does welding have on the grain-size of a metal? What effect will
pre-heating have
on the microstructure of the weld-area in high carbon steel? Show it with the help of
neat
diagram.
8. Sketch a gas welding set-up.
9. How is gas welding performed? How is the flame adjusted?
10. Sketch the three types of gas welding flames and give differences between them.
11. Give the advantages, limitations and applications of gas welding?
12. Describe gas welding techniques in detail?
13. Write short notes on :
(i) Welding rods
(ii) Fluxes
(iii) Gas flames
(iv) Working of pressure regulators
(v) Working pressure of gases in H.P and L.P welding and cutting.
14. What procedure and care will you follow in operating?
(i) A low pressure plant
(ii) A high pressure plant.
15. How will you obtain neutral, oxidizing and reducing flames using welding torch in
gas
welding?
16. What are the main requirements of a good flux used in gas welding?
17. What is a gas welding rod?
18. Give the complete procedure of gas welding.
19. Compare high pressure and low pressure gas welding
20. Sketch an oxygen cylinder. How does it differ from acetylene cylinder?
21. How will you generate and store acetylene gas?
22. Sketch a single stage pressure reduction regulator and explain its working.
23. Write short notes on the following:
(i) Hoses
(ii) Torch tip
(iii) Welding torch and its parts
(iv) Welding goggles
(v) Wire brush
(vi) Filler rod in gas welding
24. Describe the method of oxy-acetylene cutting.
 Manufacturing Processes-I

Question Bank

25. Define electric arc welding. Discuss with the help of neat sketch, the principle of
arc welding.
What is straight polarity and reverse polarity?
26. Give a list of equipments required in general for electric arc welding.
27. Explain the principle of arc-welding.
28. What do you understand by the term polarity?
29. What is the advantage of having different polarities?
30. Compare the merits and demerits of using A.C and D.C for arc welding.
31. Describe briefly the methods of carbon arc and metallic arc welding.
32. Compare A.C. power source welding with D.C. power source welding.
33. Explain the principle of atomic hydrogen welding.
34. Write short notes on :
(a) Arc crater
(b) Arc blow
(c) Electrode
(d) Flux
35. What safety precautions are associated with electric arc welding?
36. Explain carbon arc welding with neat sketch.
37. Explain TIG welding and MIG welding with its merits, demerits and application.
38. Compare TIG welding with MIG welding.
39. Explain submerged arc welding with neat sketch.
40. Explain electro-slag welding with neat sketch. Compare it with electro-gas
welding.
41. Define flux shielded metal arc welding.
42. Explain operation, equipment, advantages, disadvantages and applications of flux
shielded
metal arc welding.
43. Explain plasma arc welding with neat sketch.
44. Compare plasma arc welding and TIG welding.
45. What do you under stand by thermit welding? What are its main advantages?
46. How does thermit welding process differ from ordinary arc welding?
47. Write short notes on:
(i) Forge or smithy welding.
(ii) Leftward welding.
(iii) Rightward welding.
(iv) Vertical welding
48. What are the electrodes used in arc welding made of? What is electrode coating
and why are
they provided?
49. How is an electrode specified? What factors govern the selection of an electrode?
50. Describe the following welding methods and their specific merits, demerits and
applications:
(i) TIG welding
(ii) MIG welding
51. Describe the process of submerged arc welding stating its advantages and
limitations.
52. With the help of a neat diagram explain the process of electro slag welding.
 Manufacturing Processes-I

Question Bank

53. Discuss the method of resistance welding. What are its advantages and
disadvantages?
54. What is the main source of heat in resistance welding? Why is the control of
pressure
important in resistance welding?
55. Compare spot welding with seam welding.
56. Discuss, with the help of neat sketch, the principle of spot welding,
57. Describe in detail with set up process parameters, advantages, disadvantages and
applications
of the following:
(i) Spot welding
(ii) Seam welding
(iii) Projection welding
(iv) Upset butt welding
(v) Flash butt welding
(vi) Percussion welding
58. Write short notes on following:
(i) Soldering
(ii) Brazing
(iii) Braze welding
59. Differentiate between soldering, brazing and welding.
60. Write short notes on:
(i) Electro-gas welding.
(ii) Stud welding.
(iii) Plasma arc welding.
 Manufacturing Processes-I

Question Bank

UNIT-V
Shaping Processes for Plastics

Q.1. Give the advantages and limitations of plastic products. Plastic is substitute
material of any ferrous
or non ferrous material? Explain
Q.2. Enlist the processing of plastics in details.
Q.3. Explain with a neat sketch plastic extrusion process, give their applications.
Q.4. Explain with neat ketch calendaring process of plastic
Q.5. Explain step by step procedure of thermoforming with neat sketch.
Q.6. Classify different plastic molding processes and give its advantaged and
limitations.
Q.7. Write a short note on
a. Compression Molding
b. Transfer Molding
c. Rotational Molding
d. Reaction Injection Molding
e. Blow Molding
f. Injection Molding
Q.8. Explain in details injection moulding process
Q.9. Explain in details plunger type injection moulding press.
Q.10. Write a short note on injection moulding screw.
Q.11. Classify different types of screw used in injection moulding and explain any one
with neat sketch.
Q.12. With a neat sketch calendaring process.
 Manufacturing Processes-I

Question Bank

UNIT-VI
Sheet Metal Working
2. Write short notes on:
a) Punching
b) Piercing
c) Blanking
d) Slitting
e) Bending
f) Lancing

4. Discuss the different sheering operations performed on sheet metal.

5. Explain the difference between punching, blanking and piercing.
6. Identify the three basic types of sheet metalworking operations and explain any two of
them.
7. What is springback in sheet metal bending?
8. What is sheet metal work?
9. Write down any four sheet metal characteristics
10. What is meant by clearance?
11. What is stretching?
12. Define the term “spring back”
13. How force exerted on the form block is calculated
14. What are the formability test methods?
15. What is super plasticity of metals?
16. What is metal spinning process?
17. What is sheet metal?
18. What are Punching, Nibbling, Blanking, Piercing, and tools/machines are needed for
these processes?
19. What is deep drawing? Provide a few examples of products/parts made using deep
drawing operations.
20. What is progressive die stamping?
21. Describe shearing operations in a sheet metal work with a neat sketch
22. Describe various types of bending operations with its neat sketches
23. Explain any one method of stretch forming operation with a neat sketch
24. Explain hydro forming process with its neat sketches. State their advantage and
applications
25. Explain the power spinning process with a neat sketch .give their applications
 Manufacturing Processes-I

Question Bank

26. How magnetic pulse forming process is carried out on sheet metal? Explain peen
forming process with a neat sketch
27. What is super plastic of metal? How this process is carried out on sheet metals?
28. Classify the presses used for sheet metal working and explain any one of them.
29. Differentiate between manual press and mechanical press
30. Classify the press on the basis of number of slides and explain any two of them.
31. Classify the press on the basis of number of slides and explain any two of them.
32. Classify the press on the basis of frame and construction and explain any two of
them.
33. Explain in details “what important factors to be considered for selection of press”