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BASIC MANUFACTURING PROCESSES

BRANCH : MECHANICAL(I and II)
1
Time: 1 2 Hours Max Marks: 30
Answer Question No.1 and 2 which are compulsory and any THREE from the rest.
The figures in the right hand margin indicate marks
Q.1 Answer any three (5x1)

a. Which characteristic of material is used in forging process?

i. characteristics of elasticity of material ii. characteristics of ductility of material
iii. characteristics of plasticity of material iv. none of the above
b. In backward or indirect extrusion, _____ plunger is used
i. Solid ii. Hollow iii. No iv. both solid and hollow
c. Good surface finish and better dimensional accuracy can be achieved in
i. cold working process ii. hot working process
iii. both a. and b. iv . none of the above
d. Thermit welding.......
i.A process which uses a mixture of iron oxide and granular aluminum
ii.Accomplished by maintaining a hot molten metal pool between plates
iii.A process in which arc is maintained under blanket of flux
iv.In no welding process
e. Distortion in welding occures due to......
i. Use of excessive current ii. Improper clamping methods
iii. Use of wrong electrodes iv. Oxidation of weld pool

f. The parts produced by Powder metallurgy

i. always require machining ii. are of higher dimensional accuracy

iii. can not be heat treated iv. none of the above

g. Sintering increases

i. electrical conductivity, density and ductility ii. electrical conductivity, density and brittleness

iii. porosity, electrical conductivity and brittleness iv. porosity, density and ductility

h. In which of the following process the ductility of material decreases?

i. Hot working ii. Cold working
iii. Warm working iv. None of the mentioned

i. In which of the following forging metal is kept in the lower die?

i. Open die ii. Closed die

iii. Impression dies iv. None of the Mentioned

Q2. Answer any two (4x1)

a) Explain the sintering process used in powder metallurgy.

b) Name an extrusion process by which a tooth paste tube can be produced
c) What is the function of flux in welding?
d) Name the arc welding method in which the arc is not visible from outside.
e) Write short note on laser beam welding
f) Define arc blow . what are its effects?
g) What is ironing in deep drawing operation for sheet metal?
h) Write the various types of forging defects.
i) Name bonding agent s for core sands.

Q3. (a) With neat sketch explain the working of GTAW process and write its applications. (3)
(b) Explain working principle of Laser beam welding process with neat sketch. (2)
Q4. a) Name the common rolling defects and explain how these can be eliminated. (2.5)
b) Describe with neat sketch the hydrostatic extrusion process. (2.5)
Q5. (a) What are the differences between hot working process and cold working process? (3)
(b) Distinguish between drop forging and press forging process (2)
Q6. (a) the voltage arc gap characteristic of a machine is given by equation V= (15+30L) volts. Where L is
arc gap in mm. The machine operates with an open circuit wattage of 70volts and shot circuit current
of 700 amps. Determine the optimum arc length for which power is maximum and the corresponding
power. (3)
(b) discuss briefly resistance projection welding (2)
Q7. (a)Discuss the different sheering operations performed on sheet metal. (3)
(b) Explain the difference between punching, blanking and piercing. (2)
Q8.(a) Compare TIG welding with MIG welding. (2)
(b) Describe the process of submerged arc welding stating its advantages and limitations (3)
Q9(a) Using neat sketch describe briefly the method of extruding a hollow round collapsible tube with help of
drawing process. (3)
(b) What is impact extrusion? Explain this process and state its specific applications. (2)