15ME11T

WORKSHOP TECHNOLOGY
Question – Answers

(1st Semester Mechanical)

Unit Chapter Page No

Unit - 1 Materials for Manufacture 1
Unit - 2 Basic Manufacturing process 13
Unit - 3 Basic Fabrication Process 25
Unit - 4 Metal casting processes 41
Unit - 5 Sheet metal processes 61
Unit - 6 Powder metallurgy 71

Dr. Abdul Khader A A

Karnataka (Govt.) Evening Polytechnic, Mangaluru
 UNIT 1 : Materials of Manufacture
1. Name the different engineering material with examples (Nov-Dec 2016)
1. Steel – used for production of bars, channels, machineries etc.
2. Steel alloys - used for tools, dies, automobile parts etc.
3. Copper - used in wires, heating element, etc.
4. Aluminum - used for windows, frames, domestic articles etc.
5. Cement - used in construction.
6. Plastic – used for utility products like containers, buckets, net
7. Silicon - used in electronic components
8. Cast Iron – For machine frames

2. Define Ferrous and non-ferrous metal. Give any 4 examples of non ferrous metals.
(April-May 2019, Nov-Dec 2015)
3. State any 5 non ferrous metals (April-May 2019)

Ferrous metals and alloys refer to the metals and alloys which contain iron as the base metal

E.g.: Pig iron, Cast iron, Wrought Iron, Carbon steel, High speed steel, Alloy steels,

Non Ferrous metals : These are the metals or alloys which does not contain Iron as one of the
ingredients

E.g.: Copper, Tin, Zinc, brass, bronze, Aluminium, Silver, Gold

4. State any 5 properties of Non-ferrous metals (Nov-Dec-2017)

(i) They do not contain iron

(ii) They have lower strength and hardness
(iii) They have very low melting point compared to ferrous metals
(iv) They are non magnetic
(v) They have high resistance to corrosion

5. List differences between ferrous and non ferrous metals

Ferrous Metal Non Ferrous Metal

1 These metals contain iron
2 They are magnetic
3 Low resistance to corrosion
4 More commonly used in
Engineering structures
5 Higher strength and hardness
E.g.: Steel, Cast Iron
Do not contain iron
Non Magnetic
High resistance to corrosion
Less commonly used
Lower strength and hardness
E.g.: Copper, Zink, Tin

6. Explain ductility and malleability of metals (Nov-Dec-2017)

7. Explain, where the following properties of metals find their application (i) Ductility,
(ii) Malleability (iii) Plasticity (iv) Elasticity (v) Hardness (April – May 2018)
8. Explain plasticity and elasticity with examples (Nov-Dec-2018, April-May 2016)

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Property - Property refers to specific characteristics of metals. Properties effect both the
manufacture and use of materials. Following the commonly used properties

• Elasticity
• Plasticity
• Ductility
• Brittleness
• hardness
• malleability

Elasticity
• Elasticity is defined as the property of the metal by virtue of which it is able to retain its
original shape & size after the removal of loads.

• E.g.: Steel is an elastic material – It is used in construction due to its strength

Plasticity
• Plasticity is defined as the property of the metal by virtue of which a permanent
deformation takes place under the action of external load.

• Plasticity is the opposite of elasticity.

• E.g.: Clay is a perfectly plastic material. These can be moulded into any shape

Ductility

• Ductility is defined as the property of the metal by virtue of which it can be drawn into
wires
• The ductile materials commonly used in engineering practice are mild steel, copper,
aluminium, nickel, zinc etc.
• E.g.: Copper, Silver, Gold – These can be drawn into thin wires

Brittleness
• Brittleness is defined as the property of the metal by virtue of which it will fracture or break
without any appreciable deformation.
• Brittleness is opposite to ductility of a material. Cast iron, Glass, Concrete are the examples
for brittle materials.
• E.g.: Cast iron, Glass – These can take uniform load but can not take impact load

Hardness
• Hardness is defined as the property of the metal by virtue of which it is able to resist wear,
scratching and indentation (penetration).
• It also means the ability of a material to cut another material.
• The hardest material is diamond. – Hard materials are used to make cutting tools

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Malleability
• Malleability is defined as the property of the metal by virtue of which it can be rolled or
hammered into thin sheets.
• A malleable material should be plastic but not strong.
• E.g. of malleable materials are lead, soft steel, wrought iron, copper etc. These material can
be made into thin sheets

9. State properties and uses of Pig iron (Nov-Dec-2018)

Pig Iron
• Impure iron extracted from iron ores is known as pig iron.
• It is the basic raw material for the manufacture of cast iron, wrought iron and steel.
• It contains 4 to 5% of carbon.

Properties of pig iron

1. It is hard and brittle.
2. It cannot be magnetized.
3. It cannot be welded or riveted.
4. It does not rust.
5. It is difficult to bend.
6. It is neither ductile nor malleable.

Uses or applications of pig iron

1. It is used for manufacture of wrought iron, cast iron and steel.
2. It is not suitable for commercial use, since it has high percentage of impurities.

10. State any five properties and uses of Cast Iron (Nov-Dec-2018, April May 2017, Nov-
Dec 2015)

Cast Iron
• It has about 2% of carbon.
• It is widely used type of iron for engineering applications.
• It is manufactured by re-melting pig iron with in a furnace called CUPOLA

Properties of cast iron

1. It is hard and brittle.
2. It cannot be magnetized.
3. It cannot be riveted or welded.
4. It will not rust easily.
5. It can be hardened but it cannot be tempered.
6. Its melting temperature is 1250°C.
7. Its specific gravity is 7.5.
8. It is weak in tension and strong in compression.

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Uses of cast iron
• For making manhole covers, sanitary fittings, water pipes and gas pipes.
• For making spiral staircases, gates and lamp posts.
• For making machinery frames (where no impact loads comes).
• For preparing agricultural implements.
• For making garden seats, chairs.

11. Indicate any 5 uses of cast iron (April-May 2016) (Same as above)
12. Differentiate between pig iron and cast iron (April-May 2016, Nov-Dec 2015)

Pig Iron Cast Iron

1 High Carbon content (4% by Low Carbon content (2% by weight)
weight)
2 Obtained from Iron Ore Obtained from Pig Iron
3 More brittle Less brittle
4 Low strength High strength
5 Used for making other forms of Used for making useful products
iron

13. State any 4 uses of wrought iron (April-May 2019)

Wrought Iron
1. Wrought iron is a highly refined iron.
2. It is prepared from pig iron
3. The % of carbon is reduced to 0.02 % and other impurities removed

Properties of wrought iron

1. It is tough, malleable and ductile.
2. 3. It can be forged.
4. [t can be readily welded.
5. It rusts more quickly than cast iron.
6. It can neither be hardened nor tempered like steel.
7. High melting point.

Uses of wrought iron

1. bolts.
2. Used for chains and crane hooks.
3. Used for railway couplings, pipe and pipe fittings.
4. Used for boiler tubes

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14. Distinguish between wrought iron and steel, (April-May 2019, Nov-Dec-2017, Nov-
Dec 2016)

Steel
• It is an important engineering material widely used for engineering purposes.
• Steel is an alloy of iron and steel
• It contains carbon from 0.25 to 1.5 percent.

Properties and uses of steel

Properties
1. Good tensile, compression and shear strength
2. Excellent malleability and ductility.
3. Good machinability and weldability
4. Possess good hardness and toughness
Uses
1. Can be forged, rolled, drawn, extruded etc.
2. Nuts and bolts.
3. Structural girders, automobile bodies, etc.
4. Roof trusses

Types of steel

Dead Mild steel – : 0.05-0.1% Carbon

Low carbon steel or mild steel : 0.1 to 0.3 % Carbon
Medium carbon steel : 0.3 to 0.6 %
High carbon steel : 0.60 to 1.7 %

Wrought Iron Steel

1 Pure form of iron An alloy of iron and carbon with
other materials
2 Low tensile strength, High tensile strength, compressive
compressive and shear and shear strength
strength
4 More ductile, less elastic Hard and elastic
5 Difficult alter properties Properties can be altered by heat
by heat treatment treatment

High Speed Steel

High Speed Steel (Up to 18 % tungsten Up to 4% chromium and upto 1% Vanadium)

Properties
1. High heat resistance.
2. High hardness.
3. High compressive strength.
4. Excellent toughness and cutting ability.

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Uses: Used for drills, lathe, planer and shaper tools, milling cutters, reamers, threading dies,
punches, etc.

15. Define heat treatment and indicate any four purposes (April-May 2017, Nov Dec
2016)

Heat treatment
The heat treatment is defined as an operation involving the heating & cooling of metal or an alloy
for the purpose of obtaining certain desirable properties.

Purpose of heat treatment

1. To increase the surface hardness of the metal.
2. To relieve the internal stresses set up in the metal after hot or cold working.
3. To improve the Machinability.
4. To soften the metal.
5. To provide better heat resistance, corrosion resistance, & wear resistance.
6. To improve mechanical properties like tensile strength, ductility, shock resistance etc.

Process of heat treatment

Process of heat treatment consists of the following steps

1. Heating the metal to a specific temperature. (near or upto critical temperature)

2. Holding the metal at this temperature for a specified period;
3. Cooling (quenching) the metal according to the specified process.

16. Name different heat treatment processes (April-May 2016, Nov-Dec 2015)
(i) Annealing
(ii) Normalising
(iii) Tempering
(iv) Case hardening (nitriding)

17. Explain the following heat treatment processes (i) Normalising, (ii) Tempering (Nov-
Dec-2018)
18. Explain the following heat treatment processes (i) Annealing (ii) Hardening (April –
May 2018)
19. Explain i) Hardening ii) Normalising (April-May 2019)
20. Explain the process of (i) Annealing (ii) Tempering (Nov-Dec 2016)

Annealing
Annealing is the process of heat treatment for making steel soft so that it can be easily machined

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Purpose of annealing
• To soften the metal so that it can be easily machined.
• To relieve internal stresses induced by hot or cold working.
• To alter electrical and magnetic properties.
• To remove gases trapped in metal.

Process of annealing
• Steel is heated to a specific temperature
• It is held at this temperature for a definite period of time.
• The steel is then allowed to cool inside the furnace gradually

Applications of annealing
• It is applied to castings and forgings

Normalising
It is the process of heat treatment carried out to restore the structure of steel to normal condition

Objectives of normalizing
• To promote uniformity of structure
• To secure grain refinement
• To bring about desirable changes in properties like tensile strength
• To improve machinability

Procedure of Normalising
1. Steel is heated to about 50-55 degrees above the upper critical temperature.

2. It is held at that temperature for a short duration

3. Then the steel is allowed to cool in still air at room temperature (which is quenching in air)

Differences between annealing and normalising

Annealing
1 The objective is to improve ductility and
reduce brittleness
1 Steel parts are cooled slowly in furnace
3 Parts are comparatively soft and easily
machinable
3 Cooling process is slower
5 Parts become more ductile and less
brittle
Normalising
The objective is to reform grain
structure and make it uniform
Steel parts are cooled slowly in still air
Comparatively hard
Cooling process is faster
Does not become

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Applications of normalizing
• It is applied to castings and forgings to refine grain structure and relieve stresses

• It is applied after cold working such as rolling, stamping and hammering

Hardening
Hardening is the opposite of annealing. Here the purpose is to increase the hardness of the steel

Procedure of hardening
• Steel is heated above critical temperature range
• It is held at that temperature for specific amount of time
• The steel is then rapidly cooled in the medium of quenching (water, oil, brine etc.)
Difference between annealing and hardening
Annealing Hardening
1 Steel parts are heated and Steel parts are heated and quenched
cooled slowly in air in water
2 Objective is to soften the metal Objective is to harden the metal
4 Ductility increases Ductility decreases
5 Relieves internal stress Does not relieve internal stress

Applications of hardening
• It is applied for chisels, sledge hammer, hand hammer, centre punches, taps, dies, milling
cutters, knife blades and gears.

Tempering
• When hardening process hardens a steel specimen, it becomes brittle and has high residual
stresses.

• Tempering results in reduction of brittleness and removal of internal strains caused during
hardening.

• Steel must be tempered after hardening process

Purpose of tempering
• To relieve internal stresses caused by hardening

• To reduce brittleness

• To improve ductility, strength and toughness

• To increase wear resistance

• To obtain desired mechanical properties

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Procedure of tempering
• The steel after being quenched in hardening process is reheated to slightly below the lower
critical temperature. (around 700 degree centigrade)

• The reheating is done in a bath of oil or molten lead or molten salt. The specimen is held in
the bath for a period of time till it attains the desired temper uniformly.

• Now the specimen is removed from the bath and allowed to cool slowly in still air

Applications of tempering
• It is applied for cutting tools and gears which are hardened by hardening process

Nitriding
• It is the process of case or surface hardening in which nitrogen gas is used to obtain hard
skin of the metal.

Purpose of nitriding
• To harden the surface of steel to a certain depth

• To increase resistance to wear.

• To increase corrosion resistance

Process of nitriding
• It is done in electric furnace where temperature varying between 450 and 510 degrees is
maintained.

• The articles placed in an air tight container provided with outlet and inlet tubes through
which ammonia gas is circulated

• The container with the articles is placed in the furnace and ammonia gas is passed through it
while the furnace is heated

• During the process of heating, nitrogen gas is released from ammonia in the form of atomic
nitrogen which reacts with the surface of the article and form iron nitrate, which is very
hard.

• The depth of penetration depends upon the length of time spent at the nitriding
temperature.

• The article is taken out and it does not require any quenching or further heat treatment

Applications of nitriding
1. It is applied for hardening the surface of medium carbon alloy steels.

2. It is used in gears, shafts, valves, sprockets, cutters, boring bars and fuel injection pumps

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21. List ay five properties and uses of Copper (Nov-Dec-2018)

Copper
• It is reddish coloured metal.

Properties of copper
• It can be worked in hot and cold condition.
• It is a good conductor of heat and electricity.
• It offers good resistance to corrosion.
• It is highly ductile, malleable and soft.
• It is not attacked by dry air but moist air gives a green coating on its surface.
• It is light in weight.
• Its melting point is 1083°C and boiling point is 2300°C.
• Its specific gravity is 8.92.

Uses of copper
• It can be cast, forged, rolled and drawn into wires.
• It is widely used for making electrical cables and wires.
• It is used in heat exchangers, heating vessels and home appliances.
• It is used for electroplating and for soldering iron bits.
• Used as a coating on steel prior to nickel and chromium.
• It is used for corrosion resistant applications like sheets, boilers and condensers.

22. List any five properties and uses of aluminium (Nov-Dec-2018)

Aluminium
• It is a white metal.

Properties of aluminium
• It is silvery white metal with bluish tinge.
• It is light in weight, malleable and ductile.
• It is a very good conductor of heat and electricity.
• It is very soft and non-magnetic metal.
• It is highly resistant to corrosion and non-toxic.
• It is rarely attacked by acids.
• It possesses great toughness and tensile strength.
• Its melting point is 658°C and boiling point is 2056°C.
• Its specific gravity is 2.7.

Uses of aluminium

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 • Due to its lightweight it is used to manufacture aircraft and automobile components.
• It is used in power transmission cables, electric bulbs and electric conductors.
• It is used in cooking utensils since it is non-toxic.
• Used to manufacture window frames.
• Used in manufacture of chemical containers.
• It is widely use for mirrors, reflectors and telescopes.
• It is used in surgical instruments.
• It is used for manufacturing paints in powder form.

23. State 6 properties of plastics (Nov-Dec 2015)

Plastic
Plastic may be defined as organic material that can be easily moulded or shaped to give non-
crystalline substances that are solid at ordinary temperatures

Properties of plastic
1. Good compressive strength
2. Excellent tensile strength
3. Good machining Properties
4. Good chemical resistance
5. Can be shaped easily'
6. They are rigid.
7. High wear resistant with low density
8. Good corrosion resistance
9. Low melting Point.
10. Light and strong.
Uses of plastic
1. Used for adhesives and coatings.
2. Used for rubber compounds, resins, oils etc.
3. Used in radio cabinet, TV cabinet, computers, etc.
4. Used in electric materials
5. Used for bags, bottles etc.
6. Used for printed circuit boards, boats, etc.
7. Used for taps, Pipes, tanks etc.
8. Used for lab equipment, insulators, capacitors, etc
9. Used as floor and decorative materials
10. Used as a thermal barriers etc.

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Types of plastics
1) ThermoPlastic

2) Thermosetting Plastics

24.Explain thermo setting and thermoplastics (Nov-Dec-2018, April – May 2018, Nov-
Dec 2017)
Types of plastics
(i) Thermo plastics (ii) Thermo setting plastics

Thermo plastics
• The plastics which are softened by the application of heat without pressure and
harden on cooling are known as thermos plastic plastics.
• They can be reshaped while in the softened state and they will reharden when
cooled

Uses :
1. These are best suited for shrink fit packaging

2. Used as binding materials for grinding wheels, phonographic discs

3. Used in toilet materials, Pens, tooth brushes, radio dials etc.

Common thermoplastics: Polyethylene, P.V.C., Nylon, Silicones, Bitumen

Thermo-setting plastics
1. Thermosetting plastics are made from chains which have been linked together referred to as
a cross-linked.
2. They will not soften when heated.
3. They are practically insoluble, fireproof and usually hard and brittle.
4. These plastics cannot be reused.
5. The thermosetting plastics are popular due to their properties like hardness, rigidity and
heat resistant.

Different thermo-setting plastics : Bakelite, Melamine, Epoxy resins

25. Compare thermo plastics with thermosetting plastics (April-May 2017, Nov-Dec
2016)

Differences between Thermo plastics and thermosetting plastics

Thermo plastic Thermo setting plastics
1 Becomes soft on heating and Does not become soft on heating
can be reshaped
2 Can be recycled Can not be recycled

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 3 Weak internal boding between Strong internal bonds
chains
4 Higher cost Less cost

26. List 5 properties and 5 uses of ceramics (April – May 2018, April May 2017, April-
May 2016)
27. Write short notes on ceramics (Nov-Dec-2017, Nov-Dec 2016)

Ceramic materials
1. A ceramic material is an inorganic, non-metallic, often crystalline oxide, nitride or carbide
material.
2. E.g. Silicon, Carbon.

Ceramic materials are brittle, hard, strong in compression, weak in shearing and tension

1. These are used for cutting tools

2. Used as a thermal barriers
3. Used in fuel cells, glassware, 'dinner ware' etc.
4. Used in safety glass windshields in automobiles.
5. Used as a decorative material
6. Used in glass fibres and optical fibres
7. Used in insulators, capacitors and IC packages
8. Ceramic abrasives are used in grinding wheels, polishing wheels
9. Used in refractories, chemical industries.

28. Explain composite metals in engineering (April-May 2016)

Composite materials

• Composite materials are the combination of two or more organic or inorganic

components.
• One component acts as a "matrix" (e.g. epoxy), which holds everything together while
the other component acts as a reinforcement (e.g. glass fibre, boron fibre) in the form of
fibre embedded in the matrix.
29. Define composite materials. Indicate any four uses of composite materials (Nov-
Dec-2017, Nov-Dec 2015)

Composite materials are the combination of two or more organic or inorganic components. One
material is as base (matrix) and other material is a reinforcement

Uses of composite materials

1. High temperature structures.

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 2. Aerospace applications where light weight, stiffness and fatigue resistance are essentially
required.
3. Used in gas turbines.
4. Used in Storage battery plates.
5. High temperature engine Parts.
6. Used in nuclear reactors.
7. Electrical components.
8. Used in pressure vessels and sea mining equipment.

Properties of composite materials

1. High strength of weight ratio.
2. High stiffness to weight ratio.
3. Good wear resistance.
4. Superior magnetic Properties.
5. High modulus of elasticity.
6. Superior mechanical properties.
7. High resistance to thermal expansion.
8. Good corrosive resistivity
9. Excellent fatigue resistance.
10. Improved toughness.
11. Occupy less space.

30. Define composite material. Indicate any four of them (Nov-Dec-2018)

Composite materials are the combination of two or more organic or inorganic components. One
material is as base (matrix) and other material is a reinforcement
Examples : Reinforced concrete, plywood, reinforced plastic, fibre glass, Synthetic foam.

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