COURSE FILE

for
PRODUCTION TECHNOLOGY
(II B.Tech., II - SEMESTER)
MECHANICAL ENGINEERING

2013 - 14

CVR COLLEGE OF ENGINEERING

Vastunagar, Mangalpalli (V), Ibrahimpatan (M),
R.R. Dist. Pin : 501510.
email :info@cvr.ac.in
web : http://cvr.ac.in

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, HYDERABAD

II Year B.Tech. M.E. I-Sem
(54013)PRODUCTION TECHNOLOGY
UNIT I
CASTING: Steps involved in making a casting Advantage of casting and its applications Patterns and Pattern
making Types of patterns Materials used for patterns, pattern allowances and their construction, Principles of
Gating, Gating ratio and design of Gating systems
UNIT II
Solidification of casting Concept Solidification of pure metal and alloys, short & long freezing range alloys.
Risers Types, function and design, casting design considerations, special casting processes 1) Centrifugal 2) Die,
3)Investment.
Methods of Melting: Crucible melting and cupola operation, steel making processes, special.
UNIT III
A) Welding : Classification of welding process types of welds and welded joints and their characteristics, design of
welded joints, Gas welding, ARC welding, Forge welding, resistance welding, Thermit welding and Plasma (Air and
water ) welding.
B) Cutting of Metals: Oxy Acetylene Gas cutting, water plasma, cutting of ferrous, Non-ferrous metals.
UNIT IV
Inert Gas welding, TIG & MIG, welding, Friction welding, Induction welding, Explosive welding, Laser welding,
Soldering & Brazing. Heat affected zones in welding;
Welding defects Causes and remedies destructive nondestructive testing of welds
UNIT V
Hot working, cold working, strain hardening, recovery, recrystallisation and grain growth, Comparison of
properties of Cold and Hot worked parts, rolling fundamentals theory of rolling, types of Rolling mills and
products. Forces in rolling and power requirements
UNIT - VI
Stamping, forming and other cold working processes : Blanking and piercing Bending and forming Drawing and
its types wire drawing and Tube drawing coining Hot and cold spinning Types of presses and press tools.
Forces and power requirement in the above operations.
UNIT- VII
EXTRUSION OF METALS : Basic extrusion process and its characteristics. Hot extrusion and cold extrusion Forward extrusion and backward extrusion Impact extrusion Hydrostatic extrusion. Forging processes: Principles
of forging Tools and dies Types Forging Smith forging, Drop Forging Roll forging Forging hammers:
Rotary forging forging defects.
UNIT - VIII
Processing of Plastics: Types of Plastics, Properties, applications and their Processing methods &Equipment (blow
&injection modeling)
TEXT BOOKS :
1. Manufacturing Engineering and Technology/Kalpakjin S/ Pearson Edu.
2. Manufacturing Technology / P.N. Rao/TMH
REFERENCES :
1. Production Technology / R.K. Jain
2. Process and materials of manufacturing Lindberg/PE
3. Principles of Metal Castings / Roenthal.
4. Welding Process / Paramar /
5. Production Technology /Sarma P C /
6. Production Engineering Suresh Dalela & Ravi Shankar / Galgotia Publications Pvt. Ltd.

Unit No.

UNIT I

UNIT
II
UNIT
III

UNIT
IV

UNIT
V

UNIT VI

UNITVII

Topic to be covered

No of
Period
s

Introduction, Steps involved in making a casting,

Advantage of casting and its applications, Materials
used for making mould.
Patterns and Pattern making Types of patterns
Materials used for patterns, pattern allowances, Cores,
Core Making.
Principles of Gating, Gating ratio and design of Gating
systems
Solidification of casting Concept Solidification of
pure metal and alloys
Risers Types, function and design, casting design
considerations,
Special casting processes 1) Centrifugal 2) Die, 3)
Investment.
Welding : Classification of welding process types of
welds and welded joints and their characteristics,
design of welded joints,
Gas welding, ARC welding, Forge welding, resistance
welding, Thermit welding and Plasma (Air and water )
welding.
Inert Gas welding, TIG & MIG, welding,
Friction welding, Induction welding, Explosive welding,
Laserwelding, Soldering & Brazing. Heat affected
zones in welding;
Welding defects Causes and remedies destructive
nondestructive testing of welds
Hot working, cold working, strain hardening, recovery,
recrystallisation and grain growth, Comparison of
properties of Cold and Hot worked parts
Rolling fundamentals theory of rolling, types of
Rolling mills and products.
Forces in rolling and power requirements
Stamping, forming and other cold working processes :
Blanking and piercing
Bending and forming, Drawing and its types wire
drawing and Tube drawing coining.
Hot and cold spinning Types of presses and press
tools. Forces and power requirement in the above
operations.
EXTRUSION OF METALS : Basic extrusion process and
its characteristics.
Hot extrusion and cold extrusion - Forward extrusion
and backward extrusion, Impact extrusion Hydrostatic

3
5

Total No of
Periods.

11

3
3

2
3
4

5
2
2
3

1
3

3
2
2

2
2
1
2

extrusion.
Principles of forging Tools and dies Types Forging
Smith forging, Drop Forging Roll forging Forging
hammers: Rotary forging forging defects.
UNIT VIII

Processing of Plastics: Types of Plastics, Properties,

applications
Processing methods &Equipment (blow &injection
modeling)

Total:
UNIT-1
What is pattern? What is difference between a pattern and a casting?
Enumerate the various functions of a pattern?

61

Give the names of different metals and alloys used for making patterns. What are the advantages,
disadvantages and limitations of metal patterns?
Write short notes on the following with suitable sketches.
(i) Cope and drag pattern
(ii) Skeleton pattern.
What are the various tools used by a pattern maker?
Sketch and discuss the uses and advantages of a gated pattern.
What are the factors which govern the Selections of a proper material for pattern making?
Discuss with the help of a neat sketch the working of sweep pattern.
What are the advantages of casting process over other production processes?
Why coarser sand is is better for steel castings than fine grained sand? Why is it, that as castings
increase in size, it is often better to use increasingly coarser sand?
What is pattern makers scale? What are its uses and limitations?
Explain with neat sketches the steps involved in making green sand molding using split-pattern.
What precautions will you take to avoid distortion, cold shut and cavity formation in castings.
Explain.
How does the size and shape of the sand grains relate to moulding sand properties?
Differentiate and explain vertical and horizontal gating systems?
Explain using simple sketches the following pattern types:
i. Solid pattern.
ii. Sweep pattern.

Discuss the various types of gates that are normally used.

Calculate the size of a cylindrical riser (height and diameter equal) necessary to feed a slab
casting 25 25 5 cm with a side riser, casting poured horizontally in to the mould. Use caines
equation and take constants in caines equation as a = 0.1, b = 0.03 and c = 1.0.
UNIT-2
Write descriptive notes on:
(i) Solidification of casting
(ii) Steel making processes.
How is the centrifugal casting method used in the production of pipes?
Describe the procedure of making casting by the Investment casting process.
What is Investment casting? What are the main materials used for making an Investment Pattern?
What are the methods of applying the Investment material to the pattern?
Why directional solidification is desirable in the production of a cast product?
How do you understand by centrifugal casting? How are the centrifugal casting methods
classified?
Discuss the advantages and disadvantages of shell moulding process.
Draw the neat sketches of bottom and top gating systems and explain
Discuss some of the attractive features of the die casting process compared to alternative casting
methods.
Explain the parameters which cause the pouring time of a given casting to vary.
Explain the working of cupola furnace?
OBJECTIVE QUESTIONS:
Match List I with List II and select the correct answer using the code given below the lists :
List I
List II
A. Connecting rods
1. Welding
B. Pressure vessels
2. Extrusion
C. Machine tool beds
3. Forming
D. Collapsible tubes
4. Casting
Codes
ABCD
AB C D
(a) 2 1 4 3
(b) 3 1 4 2
(c) 2 4 1 3
(d) 3 4 1 2

Ans: (b)
Consider the following statements:
1. Hot chamber machine is used for casting zinc, tin and other low melting alloys.
2. Cold chamber machine is used for die casting of ferrous alloys
3. Rapid cooling rate in die casting produces high strength and quality in many alloys.
Which of these statements are correct?
(A) 1, 2 and 3 (B) 1 and 2 only (C) 2 and 3 only (D) 1 and 3 only
Ans: (a)
Consider the following advantages of die casting over sand casting :
1. Rapidity of the process
2. Smooth surface
3. Strong dense metal structure
Which of these advantages are correct?
(A) 1, 2 and 3 (B) 1 and 2 only (C) 2 and 3 only (D) 1 and 3 only
Ans: (b)
The proper sequence of investment casting steps is:
(A) Slurry coating pattern melt out-Shakeout Stucco coating
(B) Stucco coating Slurry coating Shakeout Pattern melt out
(C) Slurry coating Stucco coating Pattern melt out Shakeout
(D) Stucco coating Shakeout Slurry coating Pattern melt out
Ans: (c)
The method of casting for producing ornamental pieces are:
(A) Slush and gravity casting
(B) Pressed and slush casting
(C) Gravity and semi permanent mould casting
(D) Semi permanent mould and pressed casting
Ans: (c)
In light metal casting, runner should be so designed that:
1. It avoids aspiration
2. It avoids turbulence
3. The path of runner is reduced in area so that unequal volume of flow through each gate takes
place
(A) 1 and 2 only
(B) 1 and 3 only
(C) 2 and 3 only
(D) 1, 2 and 3
Ans: (a)
The relationship between total freezing time t, volume of the casting V and its surface
area A, according to Chvorinovs rule is :

Which of the following is the most suitable material for die casting?
a) Zinc and its alloys
c) aluminum and its alloys
b) Copper and its alloys
d) lead and its alloys
Which one of the following casting processes is the best suited to make bigger size hollow
symmetrical pipes?
a) Die casting
c) Shell molding
b) Investment casting
d) Centrifugal casting
In which one of the following furnaces most of the nonferrous alloys are melted?
a) Reverberatory furnace
b) Induction furnace
c) Crucible furnace
d) Pit furnace
UNIT-3
Explain the following welding joints; butt, Lap, tee, corner, plug and edge.
What are the common welding troubles, causes and remedies for them?
Explain Forge welding and resistance welding.
Draw a diagram showing the classification of welding process.
What are the advantages and disadvantages of DC and AC welding?
What are the forces acting which transfer the metal from the metal electrode to the work in
welding process?
Explain Gas welding and Arc welding.
With the help of a schematic diagram explain the constructional details and reactions involved in
Oxy-acetylene welding?
Differentiate between Solid Phase Welding and Liquid Phase Welding?
How does straight polarity differ from reverse polarity? Explain them briefly.
Differentiate between Arc and Gas welding with respect to the principle, operation application
and limitations?
Describe the applications and properties of
i. Neutral Flame

ii. Reducing Flame

iii. Oxidising flame.
Explain the principle of resistance welding with neat sketch?
UNIT-4
Explain the following:
(i) Advantage of brazing
(ii) MIG & TIG welding.
(iii) Explosive welding.
(iv) Forge welding

(v) Welding defects

(vi) Destructive & non destructive testing of
welds.

What is the difference between welding, brazing and soldering process.

Explain Laser welding and Induction welding.
State the purpose of Thermit welding. Where would you recommend it and why?
What is resistance welding? What are the main factors to be considered in Resistance welding?
Explain the term HAZ in welding and its role in the success of a weldment.
OBJECTIVE QUESTIONS:
During plasma are welding of aluminum, improved removal of the surface oxide from the base
metal is obtained with typical polarity of :
(A) DC Straight
(B) DC reverse
(C) AC potential
(D) Reverse polarity of phase of AC potential
Ans: (b)
The welding process in which bare wire is used as electrode, granular flux is used and the
process is characterized by its high speed welding, is known as:
(A) Shielded arc welding
(B) Plasma arc welding
(C) Submerged arc welding (D) Gas metal arc welding
Ans: (c)
Consider the following statements. Cast iron is difficult to weld, because of
1. Low ductility
2. Poor fusion
3. Tendency to crack on cooling
Which of these statements are correct?
(A) 1, 2 and 3 (B) 1 and 2 only
(C) 2 and 3 only
(D) 1 and 3 only
Ans: (a)
Consider an electrode coating, performing the following functions:

1. Stabilize the arc

2. Control the rate at which the
electrode melts

3. Control the flow of current.

4. Enhance the quality of the joint.

a) 1 and 2 only.
b) 2 and 3 only.

c) 3 and 4 only.
d) 1, 2 and 4.

By which one of the following methods gray iron is usually welded?

a) TIG welding
b) MIG welding

c) Gas welding
d) Arc welding

Match List I with List II and select the correct answer using the code given below the lists:
List-I
List II
A. Laser beam welding
1. Can be applied for welding or refractory metals like
niobium, tantalum, molybdenum
and tungsten
B. Electron beam welding
2. A sound and clean welded joint is created due to rubbing
of two parts against each other with adequate speed and
pressure producing intense heat raising temperature above
melting point.
C. Ultrasonic welding
3. Clean heat source created much away from job, a narrow
spot is heated, work chamber operates in a high vacuum.
D. Friction welding
4. Clean heat source very quick heating; very small focal
spot, no vacuum chamber is required.
Codes :
ABCD
(a)
4312
(b)
2314
(c)
4134
(d)
2134
Ans: (a)
A flux is used in welding to
a) Remove the oxides of the metals
formed at high temperature.
b) Permit the perfect cohesion of the
metals
UNIT-5
Explain the following:
i) Theory of rolling
ii) Re-crystallisation and grain growth
iii) cold working process.

c) Cool the metals

d) Both a and b

What are the main characteristic of the hot working as compared with cold working process.
Explain Strain hardening.
What are the advantages and disadvantages of hot rolling?
What are the different types of Rolling mills? Explain any one of them.
Describe how hot working can be used to improve the grain structure of a metal.
Discuss the following types of weld defects:
i. Hot cracking
iii. Lamellar cracking
ii. Cold cracking
iv. Solidification cracking.
Write a note on thread rolling process.
Derive an expression for driving torque and power in rolling.
A stock of thickness 30mm is to be rolled in two stages. In the first stage the reduction is to be
from 30mm to 10mm and in the second stage from 10mm to 5mm. calculate the minimum
diameter of the rolls for the two stages if the maximum angle of bite is 400 for the first stage and
300 for the second stage. Also, find the required coefficient of friction in both the stages.
A 25mm thick plate is rolled to a final thickness of 20 mm in a 4-high rolling mill. Determine coefficient of friction, Neutral section, and backward and forward slips. Also find the maximum
pressure that can be obtained in the process. Diameter of the rollers is 600mm. tensile yield stress
of the material is 100 N/nm2.
OBJECTIVE QUESTIONS:
Which one of the following statements is NOT correct for normalizing?
(A) It us often applied to casting to relieve stresses
(B) It increases strength of medium carbon steel to some extent
(C) Better surface finish can be obtained in machining
(D) It increases grain size
Ans: (d)
Which one of the following is correct?
In metal forming processes, the magnitude of stresses encountered is
A) Less than the yield strength of the material.
B) Between the yield strength and the fracture strength of the material.
C) Less than the elastic limit of the material.
D) Greater than the ultimate strength of the material.
The grin structure is refined in
a) Cold working process
b) Hot working process

c) Both a and b
d) None of the above

Choose the wrong statement

a) Cold working process requires greater force than hot working process.
b) The deformation of metals takes place by the method of slip planes in cols working
process.
c) Cold working produces an improved surface finish and scale of free surface.
d) Cold working results in increase of ductility and loss of strength and hardness of the
metal.
UNIT-6
Explain the following:
(i) Wire drawing
(ii) Types of presses and press tools.
(iii) Hot and cold spinning.
Discuss the advantage of extrusion process.
Discuss Drop forging and Roll forging.
Explain the following:
(i) Blanking and piercing
(ii) Wire drawing and Tube drawing
Differentiate hot spinning and cold spinning processes.
Discuss various types of processes used in metal forming operations.
Distinguish between open frame and closed frame of presses.
What are the various press tool components?
What is the roll of bending die? What are the different types of bending dies? With suitable
sketches explain following tools
(i) Progressive die
(ii) Compound die
(iii)Combination die.
An aluminum strip of 50mm width and 3mm thickness is bent into a 900 angle.
The data given is
Fracture strain = 0.25, _=0.1,
E=70 KN/mm2, die opening = 30 mm
Coefficient of linear strain hardening (n) = 30 N/mm2
Determine:
(a) The minimum possible bending radius
(b) The angle of the bending punch, taking care of the spring back
(c) The peak bending force.
A steel wire is drawn from an initial diameter of 12.7 mm to a final diameter of 10.2 mm at a
speed of 90m/min. the half cone angle of the die is 16 and the coefficient of friction at the job-die
interface is 0.1. A tensile test on the original steel specimen gives a tensile yield stress 207
N/nm2. a similar specimen shows a tensile yield stress of 414 N/mm2 at a strain of 0.5. Assuming

a linear stress-strain relationship for the material, determine the drawing power and the
maximum possible reduction with the same die. No back tension is applied.
OBJECTIVE QUESTIONS:
Which one of the following metal forming processes is used for manufacture of steel wires?
A) Deep drawing
B) Forging
C) Spinning
D) Drawing
The operation of cutting a hole (other than cylindrical) in a sheet of metal by the punch and die is
known as:
a) Slitting
c) Piercing
b) Blanking
d) notching
UNIT-7
Explain the following:
i) Forging hammers
ii) Forward extrusion and backward extrusion.
What are different type of forging explain any one of them.
Explain forward extrusion and backward extrusion.
Write a short notes an
(i) Forging defects
(ii) Hot extrusion and cold extrusion
(iii) Press tools.
What are the various forging defects? Discuss briefly.
What is hot extrusion? In how many ways it can be performed?
Enumerate the differences between forward extrusion and backward extrusion.
Explain the principle and relative merits of the following processes.
i. Tube Extrusion
ii. Tube Drawing
OBJECTIVE QUESTIONS:
Forging is used for making cold chisels.
a) True
b) flase
What is the major problem in hot extrusion?

A) Design of punch
B) Design of die
C) Wear and tear of the die
D) Wear of the punch
UNIT-8
What is the main advantage of injection moulding for thermo plastic parts as compared with hot
compression moulding?
What factors those influence the accuracy to which plastic parts can be moulded?
How do thermo plastics differ from thermo setting plastics?
What is the principal advantage of the casting method of moulding plastic parts?
What are the characteristics of thermo plastic plastics?
What are the good practices in the design of moulded plastic parts?
Explain different types of plastics and their properties.
What is the main advantage of Inject moulding.
Describe with the help of neat sketches the following tools used in forging operation.
i. Fullers
ii. Tongs
Explain the reasons for the following forging defects and their remedies
i. Dimensional discrepancies
ii. Decarburization
iii. Under filling
iv. Cracks.
OBJECTIVE QUESTIONS:
Which one of the following materials is best processed by injection molding?
A) All types of plastics
B) Thermoplastics
C) Non- ferrous materials
D) Thermo-setting plastics
Female half of injection mould is normally attached to
(a) Moving platen;
(b) Stationary platen;
(c) Screw;
(d) Barrel;

There are four tie bars in an injection moulding machine. What is the function of these tie bars?
(a) To provide support to screw and barrel;
(b) To provide drinks to injection moulding machine operators;
(c) To provide support to stationary and movable platen;
(d) To provide support to hopper;