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BT-106 · Manufacturing Practices/Important Questions

Manufacturing Practices (BT-106) - Important Questions

  1. Unit 37 Marks High Priority

    Explain the differences between hot working and cold working processes. Discuss advantages, limitations and typical applications of each.

    Fundamental conceptual question covering basic definitions, advantages and limitations of temperature-dependent metal forming processes; frequently asked in exams.

  2. Unit 37 Marks High Priority

    Define forging. Classify forging processes into open-die and closed-die forging. Explain the working principles, tooling arrangements and applications of both types.

    Core topic: forging types, classification and process parameters are standard theory questions.

  3. Unit 310 Marks High Priority

    For flat rolling derive the expression for true strain in terms of initial and final thickness. Hence show that true strain is given by $\epsilon=\ln\left(\frac{h_0}{h_f}\right)$ and explain its significance in rolling calculations.

    Essential derivation used frequently in numerical and theory problems in rolling; direct mathematical relation between thickness change and true strain.

  4. Unit 37 Marks Medium Priority

    A steel strip of thickness $h_0=10\ \text{mm}$ is rolled to $h_f=6\ \text{mm}$ with negligible change in width. Calculate (a) percentage thickness reduction and (b) true strain $\epsilon$ using $\epsilon=\ln\left(\frac{h_0}{h_f}\right)$.

    Typical short numerical combining concept and calculation on rolling percent reduction and true strain; common exam style.

  5. Unit 37 Marks Medium Priority

    Explain direct (forward) and indirect (backward) extrusion processes. Compare their advantages, disadvantages and typical industrial applications.

    Standard theory question on extrusion processes; often asked to test understanding of types and comparative advantages.

  6. Unit 37 Marks High Priority

    Explain the wire drawing process. Derive the expression for true strain in a single pass drawing as $\epsilon=\ln\left(\frac{A_0}{A_f}\right)$ and state how drawing force relates to the flow stress and cross-sectional area.

    Conceptual question on wire/rod drawing covering mechanics, calculation of area reduction and forces; frequent in Unit 3.

  7. Unit 310 Marks High Priority

    Describe the following sheet metal forming operations: bending, blanking, piercing and deep drawing. For each operation explain the process, tooling and common defects.

    Comprehensive question on sheet metal forming operations; high-yield topic in exams.

  8. Unit 37 Marks Medium Priority

    Define Limiting Drawing Ratio (LDR) for deep drawing. Explain how LDR is determined and discuss the factors that affect the LDR for a given material.

    Specific deep drawing concept often examined: limiting drawing ratio and process limitations.

  9. Unit 37 Marks Medium Priority

    Explain the Forming Limit Diagram (FLD). Describe how FLD is used to assess sheet metal formability and what information is obtained from FLD curves.

    Formability and evaluation topic that links theory to testing; moderate frequency in exams.

  10. Unit 37 Marks High Priority

    Derive the relation for rolling power required given roll force $F$ and roll peripheral velocity $v$. If $F$ is known, show that instantaneous power $P$ is $P=F\,v$ and discuss factors that influence $F$ and $v$ in industrial rolling mills.

    Practical manufacturing question on rolling power; simple power/force relation is routinely tested.

  11. Unit 37 Marks Low Priority

    Outline the steps involved in Powder Metallurgy (PM) process. Explain the roles of powder preparation, compaction and sintering, and list typical applications of PM components.

    General powder metallurgy overview sometimes included in forming unit; lower frequency but important for completeness.

  12. Unit 37 Marks Low Priority

    Discuss the causes and control measures of common defects in forging and sheet metal forming such as laps, cracks, surface folding and springback. Explain how die design and process parameters influence these defects.

    Tooling and defect-control question in forging and forming; lower frequency but tests applied understanding.

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