MANUFACTURING PROCESSES

STUDY QUESTIONS

CONVENTIONAL FOUNDRY PROCESSES

1) **Draw a green sand mold and indicate sprue, gate, cavity, pouring basin, parting line,
cope, drag, riser and core.
2) Why are the skin-dried molds required? How the skin dried surface is formed?
3) **Under what circumstances the dry-sand molds are prefered?
4) Why the risers are used in sand casting? Explain briefly.
5) How the “shrinkage cavity” is eliminated in the casting?
6) **The following steel slide way is going to be produced by sand casting. Design your
pattern(s) and locate the pattern(s) in the sand mold.

7) How the binding property of silica sand is improved in sand casting? Explain briefly?
8) **What is the importance of “sand fineness test” in deciding the characteristics of
sand mold?
9) Which characteristics of sand mold is determined by permeability test? Does the
permeability test reflect the actual characteristics of sand mold during the casting
process?
10) For the following part, design the necessary dry-sand cores and show their location in
the sand mold.

CONTEMPORARY CASTING PROCESSES

1) **Explain the circumstances for using permanent molds and sand molds.
2) **Compare the characteristics two parts (the same size and same geometrical
properties) produced by sand casting and die casting.
3) In die casting, the use of high pressure in pressing the metal into the cavity improves
some properties of the casting. What are those properties?
4) What are the typical metals cast by hot- and cold-chambered die casting methods?
5) **Explain briefly the die life, size of casting and production rate of casting for different
melting temperature metals used in die casting.
6) What is the meaning of single-cavity and multi-cavity mold/die?
7) In centrifugal testing, “superior physical properties” are obtained. Explain why it is so.
8) What is gravity segregation in centrifugal casting?
9) Give six examples (parts) produced by centrifugal casting.
10) In precision (or investment) casting, explain the mold structure.
11) **What types of parts are produced by investment casting?
12) How the shell does formed in investment casting? Explain briefly.

WELDING
1) Draw butt, single vee, double vee, lap, T, corner weld geometries by simple sketches.
2) Which joining metal is commonly used in soldering?
3) What are the typical heating methods of parts to be joined in soldering? Explain them
briefly.
4) **Which metals are joined in soldering method?
5) **What are the main differences in soldering and brazing techniques considering the
3rd joining metals?
6) What is the mechanism of joining in brazing?
7) What methods are used in heating the metals in brazing?
8) How the cleaning of joining surfaces is provided in brazing and soldering methods?
9) Considering the soldering and brazing techniques, which one provides better joining
strength? Why?
10) What is the mechanism of welding in forge welding? Explain briefly.
11) **What is the main application field of forge welding?
12) What is the main difficulty encountered during forge welding?
13) Explain the meaning of “state of fusion” in gas melding?
14) **Draw a gas welding torch and indicate the parts.
15) Write down the burning equations for the two zones of neutral flame in gas welding.
16) Why do we use reducing flame in gas welding? Which metals are joined by this
technique?
17) Draw an oxygen cutting nozzle indicating the flame and oxygen exits.
18) Explain the main principle of resistance welding process by using a simple sketch.
19) **Some metals can not be joined by resistance welding. Why it is so and which metals
are they?
20) How uneven sheet thicknesses or welding sheets of different thermal conductivities are
weld by using spot welding? Explain.
21) In butt resistance welding, what geometries of parts can be used?
22) Give industrial examples of butt welding?
23) Give industrial examples of induction welding?
24) How the welding performance is affected by the frequency of the current used in
induction welding? Explain briefly.
25) On a simple sketch show the arc welding process. Indicate straight polarity on the
sketch.
26) What are the functions of coating in heavily coated electrodes?
27) What are the constituents of basic coatings used in coated electrodes?
28) **What are the shielding gas(ses) used in TIG welding?
29) What are the shielding gas(ses) used in MIG welding?
30) TIG welding is applicable for light gage works. Explain the meaning of the statements.
31) Why do we use tungsten electrode in TIG instead of using another metal electrode?
32) **Mention the use of MIG with straight and reverse polarity cases.
33) If TIG, MIG and arc welding are in consideration, which one is more suitable for
robotic (automatic) welding? Why?
34) How the molten metal is provided in submerged arc welding?
35) In submerged arc welding, the maximum penetration is obtained. Why?
36) What is the function of “backing” in submerged arc welding?
37) **Give five industrial application of submerged arc welding.
38) Mention four applications of friction welding in industry.
 39) **Search the necessary pressure and rotational speed for two circular low carbon steel
rods with 20 mm diameter.
40) List the common welding defects.
41) **Which characteristics of welding lines are investigated by ultrasonic test?
42) How the bending test is performed for testing the welds?

HOT AND COLD WORKING OF METALS

1) What are the advantages and disadvantageous of hot working processes?
2) **List the names and draw the shapes of intermediate and final forms produced in
steel rolling.
3) Draw two figures showing the variations in grain structures in hot and cold rolling
process.
4) Draw schematically the progressive forging of a material in a closed-die.
5) What is the main difference in between steam hammer and gravity drop hammers?
6) **How the surface scale formed is cleaned (removed) in forging operations?
7) Give examples for shot-peening of forged parts in industry.
8) List the materials of parts commonly forged in industry.
9) **List the superiorities of parts forged compared to the ones produced by other
techniques.
10) For some sample parts from industry, collect information for number of blows and
blowing forces.
11) Compare the final properties/characteristics of parts forged by drop forging and press
forging.
12) Collect information about three forms produced by extrusion process.
13) **List the advantages and disadvantages of direct (forward) and indirect (reverse)
extrusion.
14) Draw indirect extrusion process and use the nomenclature of the parts.
15) List the advantages of cold working process over hot working.
16) Search find two sample forms produced by cold extrusion. Collect the necessary data
for the forms.
17) What the materials of dies of wire drawing process?
18) Collect information about a wire drawn (i.e. wire material, initial wire/rod diameter,
number of stations, reduction of wire diameter at each station (or reduction in area, use
of lubricant, etc.).

SHEET METAL WORKING

1) List at least seven types of sheet metal operations.
2) By using simple sketches show the difference between piercing and blanking
operation.
3) For a die used in industry, obtain the information about die and angular clearances
(give the drawing or photo of the die if available).
4) **Two holes with 25 mm diameter will be pierced on a 1.5 mm sheet made of plain
carbon steel with 28kgf/mm2. Calculate the required piercing force for the holes.
Design your punch system stepped (give the necessary dimensions) and calculate the
forces for the new design.
5) **For the bracket blanks given in figure 5.9 (b) in the class notes, calculate the percent
use of strip for both locations of blanks (the strip width is 100mm, bracket dimensions
are 60x90x12 mm (sheet thickness is 1.5mm).
6) Collect information for four parts produced by deep drawing process.
7) **The initial height and diameter of a bullet cartridge drawn from a 0.25 mm brass
sheet is 20 mm and 9 mm. Calculate the diameter of the brass blank to be used for the
process.
POWDER METALLURGY (PM)
1) PM technology is expensive. List the reasons for this. If so, why do we use this
technology?
2) Draw the flow chart of the PM process and indicate the name of the intermediate
products.
3) **Why the “particle size distribution of a powder is important? Explain.
4) Obtain a particle size distribution chart for a powder.
5) What is the definition of “compressibility” in PM for a powder?
6) **Collect apparent density, green strength density and sintered density information for
two parts produced by PM in industry.
7) List the names of processes used for producing powders.
8) **Explain the atomization process.
9) Give information about two types of powders produced by atomization process (i.e.
powder characteristics, atomization settings, gas used, gas pressure, nozzle system,
etc.)
10) For the production of copper powder, explain the electrolytic deposition technique.
11) How the iron powder is produced in reduction method?
12) List the production methods used for production of iron powder.
13) What are the typical lubricants added to the powder in PM technique. Collect
information about the amount of their additions.
14) **What is green compact?
15) Collect information of two PM parts made from iron powders. Obtain their
compression force/pressure, compression ratio, density before and after sintering
process, sintering temperature, sintering medium, porosity before and after sintering)
16) Explain briefly the solid state sintering.
17) **Explain briefly liquid state sintering. Give examples for PM parts sintered by liquid
state sintering.
18) Collect information about sintering of different PM parts (sintering temp., sintering
medium, duration, increase in density, etc.)
19) List the finishing processes for PM parts.
20) Explain briefly the production method of cemented carbide tools.
21) **Learn the mixture of powders and their amounts in the PM gears.
22) Explain shortly the structure of porous bearings.
23) Find some other applications (use) of PM parts in industry. Don’t give the applications
mentioned in the class notes.

METAL CUTTING
1) **Draw orthogonal cutting tool model and give the necessary nomenclature.
2) Draw cutting and the related forces in orthogonal cutting.
3) Mention about factors effecting forces in cutting. Which factors are more effective in
changing cutting forces?
4) **For an orthogonal turning operation power consumption of lathe when idle= 325 W,
power consumption of lathe when cutting= 2580 W, spindle speed, N = 124 rpm;
cutting speed, v = 24.5 m/min depth of cut, d = 3.8 mm; feed rate, f = 0.2 mm/rev
Find torque at the spindle, cutting force, material removal rate.
5) For a turning tool show the angles on sketches.
6) **What are the functions of tool angles?
7) What are the geometries of inserts used in metal cutting?
8) From the manufacturers cataloges, select some toolholders and their inserts for steel
turning operations.
9) List the type of insert mounting techniques to tool holders. Schematically show these
 mounting techniques.
10) **List the types of HSS tools and their applications in industry.
11) **List the types of carbide tools and their applications in industry.
12) Explain the structure and applications of ceramic tools.
13) **What are the types of chips formed? Under what cutting conditions and work
materials these types are formed?
14) What are the functions of cutting fluids in metal cutting operations?
15) **List commonly used cutting fluids in industry.
16) List and explain the terms used to describe machinibility of a material.
17) Addition of what materials improve the machinibility of steels?
18) **How the machinibility of two materials can be compared? In the machinibility
cataloges (databases) what value(s) is(are) given to indicate the machinibility of a
material?
19) What are the types of tool wear in cutting?
20) On a simple sketch show the flank and crater wear. What are the critical values
indicating the end of tool life?
21) Write down the extended Taylor’s tool life equation. Describe the variables in the
equation.
22) **A coated carbide cutting tool has 60 min tool life when cutting mild steel at 1.2 m/s.
If Taylor’s tool-life exponent is 0.25. Find Taylor’s tool-life constant, and tool life if
the cutting speed is doubled.
23) What are the parts of engine lathe? Explain briefly their functions.
24) **On a simple sketch show the cylindrical turning process.
25) What are the cutting tools used in thread cutting in a lathe?
26) List the methods of taper turning in a lathe. Show the techniques by simple sketches.
27) What are the work holding methods in turning operations?
28) Draw schematically upright drill press and radial drilling machine. Indicate the
motions by arrows.
29) What are the reasons for performing reaming operation?
30) **Classify milling operations according to the cutting tool. Show them on simple
sketches.
31) **Compare the up and down milling methods for different aspects.
32) Draw a horizontal milling machine and its components. Indicate the motions of the
machine tool.
33) **Draw a vertical milling machine and its components. Indicate the motions of the
machine tool.
34) Why the grinding operation is performed? Provide some values foe surface roughness,
dimensional tolerances, geometrical tolerances, etc.
35) Classify grinding operations.
36) **Using schematic drawings indicate the tool and work motions for cylindrical
(centerless and between centers) and surface grinding (rotary and reciprocating table).
37) List the natural and synthetic abrasives used in grinding wheels.
38) For two grinding wheels collect information for the used abrasives, their amounts,
wheel characteristics (hardness, bonding material, etc.), recommended speeds, etc.
39) **What information can be collected from the code of the grinding wheel)?
40) Draw and name commonly used grinding wheel geometries.
41) What are the purposes of honing operation?
42) Draw lapping operations and indicate motions of the tools and workpieces.