S. Y. B.

Tech (Mechanical Engineering) Subject: Manufacturing Engineering I

QUESTION BANK
Syllabus:
Unit Content
01 Hot and cold working of metals
Principles of rolling, forging, drop, press, upset, roll forging, extrusion, drawing,
spinning, effect of hot working.
Cold working processes, Cold rolling, swaging, forging, extrusion: forward, backward
and impact roll forming, tube drawing, wire drawing, spinning, shot penning, high
energy rate forming, sheet metal working, types of presses, drives, different operations
and types of dies

02 Joining processes
Arc welding- Theory, SMAW, GTAW, GMAW, FCAW, Submerged arc welding, Stud
welding Resistance welding- Theory, spot and seam projection welding processes Gas
welding Friction welding, Ultrasonic welding, Thermit welding, EBW and LASER
welding, Use of adhesive for joining, classification of adhesives, types of adhesive and
their application, surface preparation and various joints welding defects and quality

03 Foundry- Pattern making, moulding and casting
Sand casting, types of pattern material, pattern making allowances, core print moulding,
sand properties and testing, hand and machine moulding, core boxes, core making,
melting and pouring, melting furnaces- Cupola, fuel fired, electric arc and induction
furnaces. Cleaning, finishing and heat treatment of casting, defects in casting lost foam
processes, shell moulding and investment casting. Permanent mould dies casting- Die-
casting, low-pressure permanent mould casting, hot and cold chamber processing,
centrifugal casting, semi centrifugal casting and continuous casting

04 Lathe and drilling Machine
Turning and boring, lathe construction, accessories and operations. Thread cutting-
single and multi start threading, concept of speed, feed and depth of cut. Introduction to
boring Machines, Capstan and Turret lathe. Fundamentals of drilling processes, hoist,
drill geometry, tool holder, types of drilling machines, operations performed on drilling
machines, type of drill. Reaming processes and reamer types.

05 Milling, shaping and planing
Fundamental aspects, cutter types and geometry, Operations performed on milling
machine, dividing head method of indexing. Construction, working and operations
performed on shaper, planer, and broaching machines

06 Grinding
Grinding wheels, wheel marking, wheel selection, wheel mounting, types of grinding
machines. Honing, lapping, super finishing, buffing and burnishing processes


S. Y. B. Tech (Mechanical Engineering) Subject: Manufacturing Engineering I


Unit Number: 1
Hot and cold working of metals

A. Explain / Write a note on type questions:
1. Explain what is metal forming? What is the importance of metal forming.
2. Explain advantages of mechanical working processes over the other manufacturing
processes.
3. Explain elastic and plastic deformation.
4. Explain recrystallisation and recrystallisation temperature.
5. Explain hot working with its significance, advantages and limitations.
6. Explain cold working with its significance, advantages and limitations.
7. Explain rolling. Explain the principle of rolling process with neat sketch.
8. Explain different types of rolling mills with neat sketch.
9. Explain forging process with its principle and sketch if necessary.
10. Explain different characteristics of forging process.
11. Explain different forging operations and different tools used in forging process.
12. Explain different forging operations in short.
13. Explain drop forging operation with neat sketch.
14. Explain press forging operation with neat sketch.
15. Explain upset forging operation with neat sketch.
16. Explain roll forging operation with neat sketch.
17. Explain different forging defects.
18. Explain with neat sketch different hammers and presses used for forging operations.
19. Explain what is extrusion? What are different advantages of extrusion process?
20. Explain with neat sketch forward extrusion process.
21. Explain with neat sketch backward extrusion process.
22. Explain wire drawing operation with neat sketch. Discuss its advantages.
23. Explain metal spinning operation with neat sketch.
24. Explain the effect of hot working on the different properties of metal.
25. Explain tube drawing operation.
26. Explain shot penning operation.
27. Explain impact roll forming.
28. Explain high energy rate forming processes.
29. Explain sheet metal working. Explain different press operations with neat sketch.
30. Explain the presses used in sheet metal work.
31. Explain following different types of dies used in sheet metal work.
a. Cutting die
b. Forming die
c. Simple die
d. Compound die
S. Y. B. Tech (Mechanical Engineering) Subject: Manufacturing Engineering I


e. Combination die
f. Progressive die
g. Transfer die
32. Explain process of deep drawing with neat sketch.

B. Differentiate between type questions:
1. Elastic deformation and plastic deformation
2. Hot working and cold working
3. Forward extrusion and backward extrusion
4. Different presses in forging

C. Draw a neat figure/ diagram/ sketch type questions:
All figures in explain / note type questions.

D. Why / How type questions:
1. Why a recrystalliasation temperature is of much importance in metal forming?
2. How a recrystallisation temperature decided the formability of metal?


Unit Number: 2
Joining processes

A. Explain / write a note on type questions:
1. Explain the basic principle of welding process.
2. Explain classification of welding processes.
3. Explain the principle of arc welding with neat sketch.
4. Explain the principle of resistance welding with neat sketch.
5. Explain with neat sketch principle of gas welding.
6. Explain with neat sketch: Shielded Metal Arc Welding
7. Explain with neat sketch: Gas Tungsten Arc Welding
8. Explain with neat sketch: Gas Metal Arc Welding
9. Explain with neat sketch: Flux Cored Arc Welding
10. Explain with neat sketch: Submurged Arc Welding
11. Explain with neat sketch: Stud Welding
12. Explain with neat sketch: Spot Welding
13. Explain with neat sketch: Seam Welding
14. Explain with neat sketch: Projection Welding
15. Explain with neat sketch: Gas welding: Oxyacetylene Welding
16. Explain with neat sketch: Friction Welding
17. Explain with neat sketch: Ultrasonic Welding
S. Y. B. Tech (Mechanical Engineering) Subject: Manufacturing Engineering I


18. Explain with neat sketch: Thermit Welding
19. Explain with neat sketch: Electron BeamWelding
20. Explain with neat sketch: LASER Welding
21. Explain various adhesives for joining of metals.
22. Explain adhesive types, application in adhesive bonding.
23. Explain surface preparation and its importance in welding.
24. Explain various joints in welding with neat sketch.
25. Explain various welding defects with neat sketch.
26. Explain quality in welding.

B. Differentiate between type questions:
1. GMAW and GTAW
2. EBW and LASER Welding
3. Oxygen cylinder and Acetylene cylinder in Oxyacetylene welding
4. Thermosetting resin and Thermoresins
5. Arc welding and Resistance Welding

C. Draw a neat figure/ diagram/ sketch type questions:
All figures in above questions.

D. Why / How type questions:
1. How the oxidation and atmospheric contamination in welding process is avoided?
Explain its methods.
2. Why an inert atmosphere is provided in the welding process.?


















Unit Number: 2 Name: Foundry- Pattern making, moulding
S. Y. B. Tech (Mechanical Engineering) Subject: Manufacturing Engineering I


and casting
A. Explain type questions:
B. Write a note on/ short notes on type questions:
C. Differentiate between type questions:
D. Draw a neat figure/ diagram/ sketch type questions:
E. Why / How type questions:
Unit Number: 2 Name: Lathe and drilling Machine
A. Explain type questions:
B. Write a note on/ short notes on type questions:
C. Differentiate between type questions:
D. Draw a neat figure/ diagram/ sketch type questions:
E. Why / How type questions:
Unit Number: 2 Name: Milling, shaping and planing
A. Explain type questions:
B. Write a note on/ short notes on type questions:
C. Differentiate between type questions:
D. Draw a neat figure/ diagram/ sketch type questions:
E. Why / How type questions:
Unit Number: 2 Name: Grinding
A. Explain type questions:
B. Write a note on/ short notes on type questions:
C. Differentiate between type questions:
D. Draw a neat figure/ diagram/ sketch type questions:
E. Why / How type questions: