MANUFACTURING PROCESS - I

B.E. (MECHANICAL) 5TH SEM

[Time Allowed: 3 hrs] [Max Marks: 100] NOTE:- Attempt any five questions by selecting at least two from each section. Assume any missing data.

PART-A
Q1. a) What are distinguishing features between a casting and a pattern? b) Explain briefly:i) Draft Allowance ii) Shake allowance c) What is meant by core prints? Explain how they are to be provided. d) Describe the type of risers and their uses with suitable sketches. e) Design the ingate dimensions for pouring a 15 Kg casting in 10 seconds with runner having a cross section area of 625 mm2 and the two ingates of 25mm width each. Assume equal flow through gates. (4, 4, 4, 4, 4) Q2. a) Describe the operation of cupola furnace for melting cast iron with a neat sketch. b) Write short notes on:i) Centrifugal casting ii) Continuous casting c) Compare precision investment casting and shell moulding from standpoint of process, product and applications. (8, 6, 6)

Q3. a) Briefly explain the principle of rolling with a neat sketch.

b) Differentiate between hot working and cold working. c) Explain various rolling stand arrangements with neat sketches. d) Distinguish between open die and close die forging. e) List and briefly explain various forging defects. (3, 3, 4, 5, 5)

Q4. a) Distinguish between spinning and cup drawing with reference to processes and components produced. b) Differentiate between coining and embossing. c) Explain with neat sketches the difference between direct and indirect extrusion. d) Explain the following processes: i) Wire and Tube drawing ii) Swaging iii) Blanking iv) Bending (4, 4, 4, 8)

PART-B
Q5. a) Write in brief the basic steps of powder metallurgy process. b) State the advantages and disadvantages of powder metallurgy process. c) Discuss the various methods of powder manufacture. d) Explain briefly the manufacturing of self lubricated bearing with powder metallurgy process. (5, 5, 5, 5) Q6. a) What are the different types of welding joints? Explain with neat sketches.

b) Describe the types of flames obtained in oxy-acetylene gas welding process giving the applications. c) What are the advantages of AC equipment over DC equipment in arc welding? d) Briefly explain the coding method used for the electrodes used in shielding metal arc welding (SMAW). (5, 5, 5, 5) Q7. a) Explain the TIG and MIG systems of arc welding. Give the applications of each. b) Explain clearly the difference between upset welding and flash welding with neat sketches. c) Explain briefly thermit welding along with its advantages and applications. d) What are the defects that are generally found in welding? Describe their causes and remedies. (5, 5, 5, 5) Q8. Write short notes on the following:i) Briquetting and sintering ii) Hot Iso-elastic Processing iii) Resistance Seam Welding (RSEW) and Projection Welding (RPW) iv) Brazing and soldering (5, 5, 5, 5)

14/Oct/2011
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