MANUFACTURING PROCESSES

Maximum Marks: 25 2nd Mid-semester examination Time: 1 hour

Q.1) Answer any ten questions:- (110 =10)
a) What is the primary advantage of laser beam welding over electron beam welding?
b) Name any two materials used for making non-consumable electrodes for arc welding.
c) What is the difference in the chemical reactions taking place in case of oxy-fuel gas welding and
oxy-fuel gas cutting?
d) Write two advantages of solid-state welding over liquid welding.
e) What is meant by keyhole in high energy welding processes?
f) Name two forging operations.
g) What is the difference between forging hammers & presses?
h) What do you understand by elastic springback?
i) State a prominent difference between embossing and coining of sheet metal.
j) What is meant by flash in friction welding?
k) What is the difference between homogenous and autogenous welding?
l) In oxy-fuel gas welding, why does reducing flame produce a lower temperature as compared to
neutral flame?
m) How does joining of materials take place by adhesive bonding?

Q.2) Answer any six questions:- (26 =12)

a) What is meant by reverse polarity in arc welding? Why is electrode hotter than workpiece in case of
reverse polarity?
b) What is meant by stick electrode in arc welding? What is the problem associated with it?
c) Describe the process of ultrasonic welding.
d) What is roll spot welding? Show a sketch depicting its method.
e) Mention one relative advantage each of hydraulic and mechanical presses used for forging.
f) Write two advantages of indirect extrusion over direct extrusion.
g) What is meant by tube sinking? Draw a sketch showing the process.
h) What is recrystallization? What is its significance in metal working processes?

Q.3) Answer any one question:- (31=3)

a) Describe the process of riveting sheet metals with the help of neat diagrams.
b) Estimate the clearance and the maximum shearing force needed to punch a rectangular hole of
length 1 cm & breadth 5 mm in an aluminium sheet of thickness 4 mm. Given shear strength of
aluminium sheet is 0.2 GPa.
c) An aluminium wire having yield strength 300 MPa and diameter 10 mm is to be drawn using a HSS
die having draw angle 12 and ultimate tensile strength 1.6 GPa. The coefficient of friction before
conditioning was 0.25, and after acid pickling, sulling, liming and lubricating using soap solution
became 0.05. Calculate the drawing force needed for achieving a 20% reduction in area.