|| OM ||

PRODUCTION CONVENTIONAL (PAPER II)

SECTION-A
(2 marks each)

METAL FORMING
FORGING
1. Sometimes the parting plane between two forging dies is not a horizontal plane, give the main reason
for this design aspect, why is parting plane provided, in closed die forging?

DRAWING
1. Name any four materials used for making wire drawing dies and explain the application of each of
them.

ROLLING
1. What is a three high rolling mill? Indicate the movement of rolls and the work piece.
EXTRUSION
1. What is extrusion? Name the process manufacturing collapsible tubes and draw figures to show the
process.

POWDER METALLURGY
1. What is isostatic pressing of metal powders? What are its advantages?

2. Discuss the term fineness and particle size distribution in powder metallurgy.

3. Metal powders are compacted by many methods, but sintering is required to achieve which property?
What is hot isostatic pressing?

MISC
1. Differentiate between cold, warm and hot working of metals.

2. How is Bend Allowance (BA) calculated in sheet metal working?

3. Briefly explain the characteristic feature of stretch forming.
4. Name three processes of manufacturing long low carbon steel tubes.


METAL CASTING
1. What is achieved by using a metallic crystal casting? Give one application of a single crystal casting
made of wasp alloy.

2. In investment casting process two types of ceramic slurries are used. Why do we use them and in
what sequence are they applied?

3. Name the casting methods by which the following products are made:
(i) Gear blanks. (iii) Carburetors.
(ii) Blades of gas turbines. (iv) Hollow pipes.

4. What is the shape of a runner for making a sand mould? On what considerations is this shape
selected?

5. Classify the advantages of powder metallurgy process in terms of economics and capabilities of the
process, and properties of the parts made.

6. What is permeability? Permeability is more important in the basic process of sand casting than
porosity. Give one important reason for this feature.

7. What is gating system? Name and show the various elements of a gating system by means of a
diagram.

8. List four parameters to be considered in the gating design for moulds.

9. Compare die casting with investment casting w.r.t. production rate, melting point of work materials
and ability of producing complex shaped products.

10. How is the wax pattern mode for an investment casting and why is the master pattern made oversize?

11. Mention the name of the process by which the following are manufactured?
(i) Tungsten carbide tools (iii) Connecting rod
(ii) Engine cylindrical block (iv) Plastic buckets

12. Explain good gating design in molding. What are its advantages?


FABRICATION PROCESS
WELDING
1. What types of oxyacetylene flames you will use to weld
(i) Cu base metals (ii) High carbon steel? Why are all fuel lines threaded left handed?
2. Enumerate four defects caused due to residual stresses in welding joints.
3. What are advantages and disadvantages of a-c welding machine?

4. In GMAW process what is spray transfer and what gas mixtures are used?

5. Draw labeled figures to show the following, in case of Oxy-acetylene welding:
(i)Carburizing flame.
(ii)Oxidizing flame.

6. What is the principle of resistance welding? Indicate where the resistance is maximum in spot
welding operation.

7. What is diffusion welding?

8. Name any four welding processes which are employed for permanently joining two dissimilar
metals.

9. What are the relative advantages of submerged arc welding over conventional open air manual
arc welding and why?

10. What do you mean by autogeneous and homogeneous welding processes? Metallurgically
name the three distinct zones in a welded part. Enumerate the most important factor governing
the fusion welding process.

11. Write the chemical equation for the reaction going on in the oxy-acetylene flame. Where do you
get the most part of the oxygen, is it from the cylinder or the atmosphere?

METAL CUTTING
1. Write the advantages and disadvantages of climb milling. In connection with grinding define
grinding ratio.

2. In connection with surface texture define
(i) Waviness (ii) Flaws, and (iii) Lay.
List three defects found on surfaces.

3. Discuss a fixture, mentioning their materials, what are duplex fixtures?

4. What does the following marking on a grinding wheel denote?

55-C-36-D-9-S-28

5. Compare the drilling and boring operations in relation to cutting action, accuracy and applications.

6. What is the function of manipulator in a robot? Classify robots as per their path control.

7. Name four parts of feeding devices in automation.

8. A right hand helical gear is being cut on a milling machine. What changes in machine settings have
to be made to cut a left hand helical gear of same pitch and number of teeth?

9. Describe two distinguishing features of Robots, which make them different from conventional
material handling equipments.

10. What is the direction of movement of the carriage while cutting left hand thread on a lathe?

11. Distinguish between jig and a fixture.

12. What is 3 2 1 principle of location with respect to fixture design? Explain.

13. How fine through holes of diameter less than 50 microns can be made in 1.0 mm thick aluminium
sheets?

14. What are meant by A-60-K-8-V when used for a grinding wheel specification?

15. In which machine tools, teeth of internal spur gears can be cut and which one of those machine tools
works fastest?

16. Why are the lathe-spindles made hollow?

17. What is meant by Basic Length Unit (BLU) of CNC machine tools? Determine the BLU of a CNC
machine tool whose work-table is moved by a 4 mm pitch lead screw driven by a stepper motor
having 200 steps in one rotation/revolution.

18. The diameter of a mild steel rod is to be reduced from 70 mm to 65 mm by plain turning in a single
pass at speed of 300 rpm and feed of 0.4 mm/rev. Determine the material removal rate (MRR) in
cubic centimeter (cc)/min that will occur during the aforesaid machining operation.

19. Keeping the other parameters same, what will be the effect of increasing the diameter of the straight
fluted plain milling cutter on the average uncut chip thickness and why?

13. Clearances have to be provided on the press tools, what is the order of clearances for shearing
operation and deep drawing operation? On what tool will you provide the clearance in
(i) Punching operation
(ii) Blanking operation

14. What characteristics of cellular manufacturing system?

15. What is meant by interpolation in CNC programming? What for are G and M codes used in NC
part programming?

16. State any four basic elements of a Robot. Give one line statement for each.

17. What is standard marking of grinding wheel? What each parameter indicates?


CUTTING TOOLS
1. Show crater wear and flank wear on a single point cutting tool. State the factors responsible for wear
on the turning tool.

2. What is meant by hot hardness, in case of tool material? Name any two tool materials which are not
suitable for low speed applications.

3. Draw sketch showing various angles of single point cutting tool for turning aluminium alloys.

4. Name two criteria for cutting tool life.

5. How does application of cutting fluid help in reducing cutting forces and improving tool life and
surface quality?

6. Cast iron with impurities of carbide requires a particular rake angle for efficient cutting with single
point tools, what is the value of this rake angle, give reasons for your answer?


NON TRADITIONAL MACHINING PROCESS

1. Comment on the machined surface characteristics obtained after the EDM process.

2. Name any four flushing methods used in EDM process. What type of flushing method is
recommendable in cases of very small size hole drilling?


LIMITS, FITS AND TOLERANCES
1. What is meant by interchangeable manufacturing? Discuss a Go gauge.

2. Name three types of fits and show a labeled diagram of a clearance fit.

3. What do you understand by Selective Assembly process? How is the range of clearance reduced?

4. Distinguish between unilateral and bilateral tolerances for the dimensions. Indicate the tolerance
zones for each by taking an example.

5. What is the whole basis and shaft basis of fits? Which one is preferred in practice and why?

6. What is the principle of angle dekkor auto collimator? What is its application?

MISC
1. An array of 50 integer numbers is to be read by FORTRAN program. Write the program lines for the
same.

2. Pointers are commonly used in C for creating linked lists. Write a FORTRAN code to implement
pointers, that is, to traverse the linked list.

3. What are pointers? Explain their use with a suitable program.

4. With the following printf ( ) statements in C, express how the value x = 38.4625 appears:
(i) printf (% 7.2 f, x)
(ii) printf (% 7.4 f, x)
(iii) printf (% f, x)
and (iv) printf (% 7.2 f, x).

5. What for FORTRAN commands REAL and DIMENSION are used and what are their equivalents in
C language?

6. What is a critical path? Why is the critical path of such importance in large project scheduling and
control? Can a critical during the course of project? To print the values of array a in the order given
below, write the source code in FORTRAN and in C :

a
11
a
21
a
31
a
41
a
51
a
12
a
22
a
32
a
42
a
52
a
13
a
23
a
33
a
43
a
53
a
14
a
24
a
34
a
44
a
54