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Recent Twomarks Document

The document discusses various manufacturing processes and techniques. It provides definitions and comparisons of processes like progressive solidification vs directional solidification, as well as differences between related machining operations like counterboring vs countersinking. Various casting defects and parameters that affect machinability are outlined. Advantages and applications of processes like resistance welding, compression molding, and stretch forming are summarized.

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Aravind Phoenix
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127 views6 pages

Recent Twomarks Document

The document discusses various manufacturing processes and techniques. It provides definitions and comparisons of processes like progressive solidification vs directional solidification, as well as differences between related machining operations like counterboring vs countersinking. Various casting defects and parameters that affect machinability are outlined. Advantages and applications of processes like resistance welding, compression molding, and stretch forming are summarized.

Uploaded by

Aravind Phoenix
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Manufacturing Technology (ME-6352)-Two marks

1. What is the difference between progressive solidification and directional solidification?


Progressive solidification involves the transformation metal in to the solid
state.Directional solidification is used to describe the aspect of freezing process and which it is
controlled from the zone of freezind area to the riser to prevent shrinkage voids during freezing.
2. What are the common allowances provided in the pattern ? why?
i) Shrinkage allowance
ii) Machining allowance
iii) Taper allowance
(iv) Shake and distortion allowance
3. What are the limitations of resistance welding process?
1. Amount of current passing through the work piece
2. The pressure that electrodes that transfers to the work piece.
3. Time during which the current flows
4. Area of electrode tip in contact with the workpiece.
4. Give the causes and remedies for undercut and hot cracking?
Adjacent to the weld, the formation of groove is called undercut. Due to non uniform
feed of welding rod, improper position of the electrode or excessive heating.
Hot cracking due to lot of stresses set up by non uniform heating and cooling, excess
sulphur or phosphorous in the weld metal.
5. What are the differences between shaper and planer?
Shaper is a reciprocating type of machine tool intended primarily produce flat surfaces
may be horizontal,vertical,or inclined.
Planer is a machine tool primarily intended for machining large flat surfaces ,these
surfaces may be horizontal, vertical or inclined. Planer is capable of machining heavy work
pieces which cannot be accommodated in shaper table.
6. Give the difference between counter boring and counter sinking?

Counter boring: It is the operation of enlarging a entry of the drilled hole by using
counter boring tool to accommodate the bolt head etc.
Counter sinking: It is the operation to bevel the top of a drilled hole for making a conical
seat.counter sink tool is used for this operation.
7. What is thermoforming and write its applications?
It is a series of processes for forming thermo plastic sheet or film over a mould with the
application of heat and pressure.which is used for making flat wares ,gears
,buttons,buckles,knobs,handles,electrical and electronics components and washing machine
housings and agitators.
8. What are reinforced plastics?
These plastics are laminated with the fibres, asbestos, boron, cotton and nylon fibres.the
reinforced plastics are used for storage bins, machinery housings, aircraft panels.
9. What is spring back? How it overcome in sheet metal work?
Spring back is beyond as the movement of the metal to resume its original position
causing a
Decrease in bend angle after the applied force is withdrawn.
10. What are the various forging defects?
Cold laps Die shift Cracks Flakes De carbonization
11. List out the basic ingredients of molding sand and their purpose?
The principal ingredients of moulding sands are a)silica sands and grains b)clay
c)moisture d)miscellaneous materials. Silica is the granular quartz ,itself a sand impart
refractoriness,chemical resistivity and permeability to the sand. Clay imparts the bonding
strength to the molding sand ,so that the mould does not lose its shape after ramming.
12. Define the term green strength and explain its importance in the context of molding?
This property of sand in its green or moist state is known as green strength. A mould
having adequate green strength will retain its shape and will not distort or collapse even after the
pattern is removed from the molding box.
13. Explain the term weld ability and give two examples of metal and alloys?

Weld ability is defined as the capacity of the material to be welded under fabrication
conditions imposed in a specific and suitably designed structure to perform satisfactorily in the
intended service. Mild steel, cast iron, stainless steel, aluminum alloys, magnesium alloys.
14. Give the advantages of resistance welding?
1. Very little skill
2. High production rate
3. Heating is confined to small area
4. No flux and no filler rod required.
5. Semi automatic equipments are available
6. Similar and dissimilar metals can be welded.
15. What are the factors affecting mach inability?
1. Metal of casting
2. Machining method used
3. Casting method used
4. Shape and size of casting
5. Amount of finish required on the machined portion.
16. Write the functions of dielectric fluid in EDM process?
1. To keep away the chips from the welding area
2. To accelerate the EDM machining process
3. To act as a cooling medium.
17. State three types of compression molding and their utilities?
Compression molding is used for making flat wares, gears, buttons, buckles, knobs,
handles, electrical and electronics components and washing machine housings and agitators.

18. What are the different types of castings?


Conventional method: Green sand mould casting, dry sand mould casting
Unconventional methods:
19. What are the casting defects?
(i) Dirt
(ii) Porosity
(iii) Blow
(iv) Dross
(v) Scab
(vi) Gas hole
(vii) Scar
(viii) Inclusion
(ix) Blister
(x) Pinholes
20. State the working principle of oxyacetylene welding process?
When acetylene in correct proportion, is mixed with oxygen in welding torch and ignited then
the flame resulting at the tip of the torch is sufficiently hot to melt and join the parent metals.
21. List out the limitations of electron beam welding?
(i) Initial cost of equipment is high and portable equipment is rare
(ii)Work is to be manipulated through vacuum seals.
(iii)Time and equipment is required to create vacuum very time a new job
is to be welded.
(iv) Precaution are needed to prevent damage from X-rays
22. Give the applications of EDM?
1. Micro machining, 2.micro drilling 3. Machining injector nozzle for diesel engines.

23. State the working principle of blow molding?


In blow molding, the plastic is fed in a granular form in to the heated section,In this heated
section the granular form melted in to the liquid and fed in to themould. The air is forced in to
the mould which forces the plastic in to sides ,give the shape of mould.The mould is cooled and
removed.
24. State the difference between extrusion and wire drawing?
The extrusion process consists of compressing a metal inside a chamber to force it out through a
small opening which is called die.
25. What are the advantages of special casting process over sand casting processes?
(i) Greater dimensional accuracy
(ii) Higher metallurgical quality
(iii) Lower production cost
(iv) High production rate
26. What are the three types of centrifugal casting?
(i) True centrifugal casting
(ii) Semi centrifugal casting
(iii) Centrifuge casting
27. What are the methods involved in brazing?
(i) Torch brazing
(ii) Furnace brazing
(iii) Induction brazing
(iv) Resistance brazing
(v) Dip brazing
(vi) Infrared brazing
28. What are the advantages of compression moulding?
Little waste (no gates, sprues, or runners in many molds)
Lower tooling cost than injection molding
Good surface finish

Less damage to fibers


Process may be automated or hand-operated
Material flow is short, less chance of disturbing inserts, causing product stress, and/or eroding
molds.
29. What are the disadvantages of compression moulding?
High initial capital investment
Labor intensive
Secondary operations maybe required
Long molding cycles may be needed.
30. Define cold moulding.

Charge is pressed into shape while cold then cured in an oven. Economical but usually poor
surface finish.
31. Define extrusion process.
Extrusion is the process of squeezing metal in a closed cavity through a tool, known as a die
using either a mechanical or hydraulic press.
32. What are the advantages of stretched forming operations?
1. Blanks can be stretched in a single operation
2. No need of any heat-treatments before and after the stretching process.
3. Spring back is reduced or eliminated when compared to other forming methods
4. Direct bending is not introduced
33. List out the applications of stretch forming operations.
1. Production of aircraft wing and fuselage parts.2. Production of contoured panels for truck
trailer and bus bodies in automobile industry

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