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7/26/2019 Other Questions Word Document

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UNIT-I

CASTING

1. What is foundry?

Foundry is the process of forming metallic products by melting the metal, pouring

in to a cavity known as the mould.

2. What are the stages of casting process?

1. Mould making

2. lamping

!. "ouring

#. cooling

$. removal

%. trimming

!. What are the different types of pattern?

1. &ingle piece pattern

2. split pattern

!. match plate pattern

#. cope and drag pattern

$. gated pattern

%. loose piece pattern

'. sweep pattern skeleton pattern

(. segmental pattern

). &hell pattern

#. What are the properties of moulding sand?


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a. grain si*e and shape

b. porosity

c. refractoriness

d. strength

e. plasticity

$. What are the important methods of sand testing?

+ Moisture content test

+ lay content test

+ rain fitness test

+ &trength test

%. What are the steps involved in refractoriness test?

+ heating the specimen at 1$--o for 2 hours

+ observe the changers in dimension and appearance

+ if the sand is good, it retain specimen share and show very littleepansion. /f the sand is poor, specimen will shrink and distort.

'. What are the pattern materials used?

+ Wood and wood materials

+ Metal and alloy

+ "lasters

+ "lastic and rubber

+ Waes.

(. What are the various types of pattern allowance?

0i &hrinkage allowance


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0ii Machining allowance

0iii aper allowance

0iv &hake and distortion allowance

). What are the basic steps in core making process?

0i core sand preparation

0ii core making

0iii core baking

0iv core finishing

1-. What is mean by core?

3 core is a part used in casting and moulding processes to produce internal cavity

and reentrant angles.

11. 4ame the three types of core binders?

0i hermoplastic binders

0ii hermosetting binders0iii ore oils

0iv lays

12. What are the types of cores?

0i reen sand cores

0ii 5ry sand cores

0iii 6il bonded cores

0iv 7esin bonded cores

0v &odium silicate and 62 cores

1!. What are the tools used in moulding process?


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0i &hovel

0ii 7iddle

iii 7ammer

0iv &trike8off bar

0v 9ent wire

0vi :ifter

0vii rowel

0viii &wab

1#. What are the types of moulding processes?

0i reen sand moulding

0ii 5ry sand moulding

0iii :oam moulding

0iv Metal moulds

0v ;ench moulding0vi Floor moulding

0vii &weep moulding

1$.


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0ii >olt machine

0iii >olt s=uee*e machine

0iv &and slinger

1%. 4ame the different *ones in upola furnace?

0i ombustion or oidi*ing *one

0ii 7educing *one

0iii Melting *one

0iv "reneating *one

0v &tack

1'. What are the advantages of special casting process over sand casting

processes?

0i greater dimensional accuracy

0ii higher metallurgical =uality

0iii lower production cost

0iv high production rate

1%. What are the three types of centrifugal casting?

0i true centrifugal casting

0ii semi centrifugal casting

0iii centrifuge casting

1'. What are the advantages of ceramic mould casting?

0i high production rate are possible

0ii no cores are needed

0iii comple shapes can caste


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0iv machining can be eliminated

0v long lead time are needed

0vi to develop new casting

1(. What are the defects in casting processes?

0i 5irt

0ii "orosity

0iii ;low

0iv 5ross

0v &cab

0vi as hole

0vii &car

0viii /nclusion

0i ;lister

0 pinholesUNIT-II

WELDING

1. 5efine welding.

Welding is a materials oining process in which two or more parts are oined

together.

2. What are the types of welding processes?

0i 6yfuel gas welding

0ii 3rc welding

0iii 7esistance welding


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0iv &olid state welding

0v @ni=ue welding

!. 4ame the e=uipments used in gas welding?

0i oygen gas cylinder

0ii acetylene gas cylinder

0iii oygen pressure regulator

0iv acetylene pressure regulator

0v oygen gas hose 0blue

0vi acetylene gas hose 0red

0vii welding torch

0viii filler rod and flues.

#. 4ame the e=uipment used in arc welding

0i 3rc welding power source

0ii welding cables0iii electrode holder

0iv welding electrode

0v welding helmets and shields

$. What are the advantages of submerged arc welding?

a. ;ecause of thigh heat concentration, considerably higher welding speed

can be used.

b.


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"lasma arc welding in an arc welding processes wherein coalescence is produced

by the heat obtained from a constructed arc setup between a tungstenAalloy

tungsten

electrode and water cooled no**le or between a tungsten alloy tungsten electrode

and the ob.

'. What are the disadvantages of plasma arc welding?

a. Welders need ear plug because of unpleasant, disturbing and damaging noise.

b. More chances of electrical ha*ards are associated with this process.

(. What are the procedures followed in hermit welding?

a. clean the oint

b. allow the concentration

c. construct the mould

d. preheating the mould

e. crucible and its charging

). What are the e=uipments used in electron beam welding?

a. 3n electron beam gun with a high voltage power supply and controls

b. a vacuum pumping system

c. mechanical tooling fitures

d. a beam alignment system

1-. What are the disadvantages of electron beam welding?

0i /nitial cost of e=uipment is high and portable e=uipment is rare

0iiWork is to be manipulated through vacuum seals.

0iiiime and e=uipment is re=uired to create vacuum very time a new ob


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is to be welded.

0iv "recaution are needed to prevent damage from B8rays

11. What is meant by friction welding?

Friction welding is a solid state welding process wherein coalescence is produced

by the

heat obtained from mechanically induced sliding motion between rubbing surfaces.

12. 5efine 5iffusion bonding.

5iffusion bonding is a solid state process wherein coalescence of the faying

surfaces is

produced by the application of pressure and elevated temperature to carefully

cleaned and

mated metal surfaces so that they actually grow together by atomic diffusion.

1!. What are the defects in welds?

a. cracks

b. distortion

c. incomplete penetration

d. inclusions

e. porosity and blow holes

f. poor fusion

1#. 5efine ;ra*ing.

;ra*ing is a oining process in which a filer metal is melted and distributed by

capillary

action between the faying surfaces of the metal parts being oined.

1$. What are the characteristics features of filler metals and flues?


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a. melting temperature must be compatible with base metal.

b. low surface tension in li=uid phase for good wettability

c. high fluidity for penetration into the interface.

1%. What are the methods involved in bra*ing?

0i orch bra*ing

0ii Furnace bra*ing

0iii /nduction bra*ing

0iv 7esistance bra*ing

0v 5ip bra*ing

0vi /nfrared bra*ing

1'. 5efine soldering?

&oldering is similar to bra*ing and can be defined as a oining process in which a

filler

metal with melting point not eceeding #$-o is melted and distributed by

capillary action

between the faying surfaces of the metal parts being oined.

1(. What are the advantages of soldering?

i low energy input relative to bra*ing and fusion welding

ii variety of heating methods available

iii good electrical and thermal conductivity in the oint

iv easy to repair and rework

1). What is adhesive bonding?

3dhesive bonding is a oining process in which a filler material is used to hold two

or


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more closely spaced parts together by surface attachment. he filler material that

binds the

parts together is the adhesive.

2-. What are the advantages of adhesive bonding technology?

a. he adherents are not affected by heat

b. @niform stress distribution

c. "ossibility to oin large surfaces.

d. "ossibility to oin different materials

e. as proof and li=uid tigh.

UNIT-III

MACHINING

1, 5efine cold working of metals?

hose process, which are working below the recrystalli*ation temperature, are

called cold

working of metals

2, 5efine the process of mechanical working of metal?

Mechanical working process are based on permanent changes in the shape of body

due to

some etreme forces

!, ive some eamples for mechanical working of metal?

7olling Forging

Ctrusion 5rawing "ress working

#, 5efine hot working of metals,


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hose process which are working above the recrystali*ation temperature is known

as hot

working of metals

$, 3dvantages of cold working over hot working

ood surface finish

;etter dimensional accuracy

%, lassifications of rolling mills

wo high rolling mill hree high rolling mill

Four high rolling mill Multi high rolling mill

@niversal high rolling mill

', 3dvantages of cold rolling

/mproves mach inability

/mprover physical properties

ood surface finish and high accuracy

(, 5efine forging

Mechanical working of metals by which metals and alloys are elastically deformed

by the

application of compressive force is known as forging process

), lassification of forging process

6pen8die process lose8die process

1-, &ome hand tools , which is used in the forging operation

&wage block hisels Fillers


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11, ypes of force weld

:ap weld ;utt weld or ump weld 9 finished weld

12, 5efine etrusion process

/t is defined as the ratio of the cross sectional area of the billet to the cross section

area of

the product

1!, What is meant by cold and hot spinning process

old spinning process is the operation of shaping very thin metal by pressing

against ;rass

wheel


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Ctrusion "iercing.

1), 5efine forge ability

/t is defined as utility of a materials to deform before cracks appear on the metal

2-, 5efects in rolling parts

&urface defects /nternal structure depicts :amination

UNIT-IV

FORMING AND SHAPING OF PLASTICS

1. 5efine plastics.

Materials that can be reshaped 0remolded by applying heat and pressure. Most

plastics are

made from synthetic resins 0polymers through the industrial process of

polymeri*ation. wo

main types of plastics are thermoplastics and thermosets.

2. Write types of plastics.

hermoset8


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hermal /nsulation


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Mold pieces 0define the geometry of the part, and sprue, gates, runners, vents,

eection pins,

cooling system.

'. 5efine compression moulding.

he process of molding a material in a confined shape by applying pressure and

usually heat.

(. 5efine transfer moulding.

3 process of forming articles by fusing a plastic material in a chamber then forcing

the whole

mass into a hot mold to solidify.

). What are the advantages of compression moulding?

+ :ittle waste 0no gates, sprues, or runners in many molds

+ :ower tooling cost than inection molding

+ ood surface finish

+ :ess damage to fibers

+ "rocess may be automated or hand8operated

+ Material flow is short, less chance of disturbing inserts, causing product stress,

andAor eroding

molds.

1-. What are the disadvantages of compression moulding?

+


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11. 5efine cold moulding.

harge is pressed into shape while cold then cured in an oven. Cconomical but

usually poor

surface finish.

12. 5efine etrusion process.

Ctrusion is the process of s=uee*ing metal in a closed cavity through a tool,

known as a die

using either a mechanical or hydraulic press.

1!. 5efine rotational moulding.

@sed to form hollow seamless products such as bins. Molten charge is rotated in a

mold in two

perpendicular aes simultaneously, or rotated while tilting.

1#. 5efine foam moulding.

Foaming agent is combined with the charge to release gas, or air is blown into

miture while

forming.

@sed to make foams. 3mount of gas determines the density.

1$. 5efine vaccum forming.

/t is accomplished by heating the plastic sheet until it is pliable enough to be

vacuumed either

into a female mold or over a male mold.

1%. 5efine spinning.

Modified form of etrusion in which very thin fibers or yarns are produced is

called spinning.

1'. 5efine calendaring.


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Molten plastic forced between two counter8rotating rolls to produce very thin

sheets e.g.

polyethylene sheets.

1(. 5efine rotational moulding.

@sed to form hollow seamless products such as bins. Molten charge is rotated in a

mold in two

perpendicular aes simultaneously, or rotated while tilting.

1). 5efine thermoforming.

&heet material heated to working temperature then formed into desired shape by

vacuum

suction or pressure.

2-. Cplain various plastics used for blow moulding.

+


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2. 9arious sheet metal that can be formed in press working

Funnels bends boes pipe covers etc.

!. What are the various measuring tools used in sheet metal operations

&teels rule, folding rule, circumference rule, vernier calipes, micrometer, thickness

gauge and

steel metal gauge

#. What is mean by clearance

learance is the intentional space between the punch cutting edge and the die

cutting depends

on the type cutting operation the space between punch and die is provided known

us clearance

$. Mention the effect of insufficient clearance,

/t does not allow a clean break but partial break occurs. /t is also called as

secondary shear.

%. What is meant by seaming?

he process of providing lock between the two edges of the different work metal is

called

seaming.

'.


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&pring 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.

1-. &tate the methods of stretch forming process

1. Form8block method

2. Mating8die method

11. What are the advantages of stretched forming operations?

1. ;lanks can be stretched in a single operation

2. 4o need of any heat8treatments before and after the stretching process.

!. &pring back is reduced or eliminated when compared to other forming methods

#. 5irect bending is not introduced

12. :ist out the applications of stretch forming operations.

1. "roduction of aircraft wing and fuselage parts.2. "roduction of contoured panels

for truck

trailer and bus bodies in automobile industry.

1!. Mention the various materials used for making dies and form blocks in stretch

forming

process.

Wood, masonite, *inc alloys and cast iron.

1#. &tate the law of process of fracturing in formability.

he ductility of the same material is lower if the section si*e is larger.

1$. &tate the law of geometrical similitude.

1. ;lanks are geometrically similar in all aspects with respect to another blank such

as


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dimension, thickness, width, length etc. hese geometrically similar blanks should

be

fabricated by using similar tools.

2. @nit strains at corresponding locations are identical for geometrically similar

blanks.

!. he forces re=uired to form any re=uired shape on geometrically similar blanks

are directly

proportional to the s=uare of the thickness.

#. he consumption of work for forming the re=uired shape is also proportional to

the cube of

its thickness for geometrically similar blanks.

1%. What are the formability test methods?

1. Formability tests for bulk deformation.

2. Formability test for elastic8plastic deformation and

!. &imulative tests for forming operation

#. Full scale forming tests

1'.


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1(. Mention the various types of simulative tests carried out for various cup

forming process.

1. Crichson test

2. 6lsen test

!. &urift test

#. Fukui test

1). What are the applications of forming limit diagram?

1. he new of tools in easy, hard or impossible to work be easily determined

2. ood materials used n forming operations are identified.

!. :ocation of source of trouble is also easy from a reference pressing by the

designer.

2-.

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