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BT-106 · Manufacturing Practices/Important Questions

Manufacturing Practices (BT-106) - Important Questions

  1. Unit 17 Marks High Priority

    Explain the step-by-step sand casting process. Draw a neat schematic of the process and discuss the purpose of each major step.

    Core process questions from Unit 1 covering sequence and practical considerations in sand casting.

  2. Unit 17 Marks High Priority

    Explain the modulus method for riser design. Define the modulus $M$ and state how it is used to decide the size of a riser. Give a worked example for a simple cylindrical riser.

    Fundamental riser design question using the modulus (feeding) concept from Unit 1.

  3. Unit 27 Marks High Priority

    Differentiate between open-die forging and closed-die forging with respect to process steps, tooling, typical products, advantages and limitations.

    Core comparative and application question from Unit 2 on forging processes.

  4. Unit 27 Marks Medium Priority

    Describe the classification of rolling mills. Explain the factors affecting rolling force and the significance of roll pass design.

    Basic rolling theory and practical mill classification from Unit 2.

  5. Unit 37 Marks High Priority

    State and explain Taylor's tool life equation and discuss the influence of cutting speed, feed and depth of cut on tool life. The Taylor equation is $V T^{n} = C$, where symbols have their usual meaning.

    Fundamental cutting tools and tool life relationship question from Unit 3; common in exams for machining theory.

  6. Unit 37 Marks High Priority

    Explain the meaning of surface roughness parameter $R_a$. How is $R_a$ measured and what are typical values for machined surfaces?

    Surface finish and measurement fundamentals from Unit 3; essential conceptual question.

  7. Unit 47 Marks High Priority

    Compare TIG (GTAW) and MIG (GMAW) welding processes in terms of equipment, electrode/filler usage, shielding, advantages, limitations and typical applications.

    Core welding methods comparison from Unit 4; frequently required in descriptive answers.

  8. Unit 410 Marks Medium Priority

    Explain the principles, applications and limitations of the following NDT methods: Ultrasonic Testing (UT), Radiographic Testing (RT) and Magnetic Particle Testing (MT).

    Non-destructive and destructive testing overview from Unit 4; standard theory question.

  9. Unit 514 Marks High Priority

    Draw a typical T-T-T (Time-Temperature-Transformation) diagram for eutectoid steel and explain the formation of pearlite, bainite and martensite during continuous cooling. Discuss the effect of cooling rate on the microstructure and properties.

    Core heat treatment conceptual question from Unit 5 focusing on phase transformations for eutectoid steel.

  10. Unit 57 Marks Medium Priority

    Describe Brinell, Rockwell and Vickers hardness tests. Explain the principles, typical scales and applications of each method.

    Essential hardness testing methods question from Unit 5.

  11. Unit 310 Marks Medium Priority

    Explain the principal components of a CNC system and outline the basic structure of a part program. Give examples of commonly used G-codes and their functions.

    CNC fundamentals question bridging machining theory and modern manufacturing (Unit 3/5 topics).

  12. Unit 57 Marks Medium Priority

    Describe the main categories of additive manufacturing processes. Discuss advantages, limitations and typical applications of 3D printing in industry.

    Additive manufacturing overview from modern manufacturing topics; growing importance in syllabi.

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