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BT-106 · Manufacturing Practices/Important Questions

Manufacturing Practices (BT-106) - Important Questions

  1. Unit 114 Marks High Priority

    Explain the steps involved in the sand casting process. Describe common casting defects and give remedies for each defect.

    Core topic: Sand casting process, defects and remedies; fundamental foundry knowledge.

  2. Unit 17 Marks Medium Priority

    Describe the different types of patterns used in foundry practice. Explain pattern allowances and the purpose of each type of allowance.

    Fundamental pattern making concepts and allowances; commonly examined in theory questions.

  3. Unit 214 Marks High Priority

    Explain the rolling process. Derive the expression for roll separating force for a strip of width $b$ undergoing thickness reduction from $t_1$ to $t_2$ under plane strain assumptions. State all assumptions made.

    Core plastic deformation process; derivation and understanding of rolling mechanics is standard in exams.

  4. Unit 27 Marks Medium Priority

    Differentiate between open-die forging and closed-die forging. State typical applications and list common forging defects with causes and remedies.

    Basic forging classification and defect awareness; often asked as short theory question.

  5. Unit 37 Marks High Priority

    Define cutting speed, spindle speed and feed. Calculate the cutting speed $V$ in m/min for a turning operation given the spindle speed $N$ in rpm and work diameter $D$ in mm using the relation $$V=\frac{\pi\left(D\right)N}{1000}.$$ Compute $V$ for $D=50\,\text{mm}$ and $N=1200\,\text{rpm}$.

    Essential machining calculation combining definitions and numerical computation; frequently appears in numerical sections.

  6. Unit 37 Marks Medium Priority

    State Taylor's tool life equation and explain the meaning of each constant. How is this equation used to select cutting parameters in production?

    Tool life equation is core to machining theory; both concept and numerical use are commonly tested.

  7. Unit 410 Marks High Priority

    Explain the principle of arc welding. Discuss commonly used arc welding processes, list typical welding defects and describe remedies for each.

    Arc welding fundamentals, process classification, defects and remedies; high-yield theory topic.

  8. Unit 45 Marks Medium Priority

    Compare oxy-acetylene welding and electric arc welding with respect to heat source, applications, advantages and limitations.

    Comparative short question often used to test conceptual clarity between welding processes.

  9. Unit 47 Marks Medium Priority

    Explain the principle of spot welding. Describe the main process parameters, typical applications and limitations of spot welding.

    Resistance welding (spot welding) is a common practical process; parameters and applications are frequent short-answer topics.

  10. Unit 514 Marks High Priority

    Explain the following heat treatment processes: annealing, normalizing, hardening and tempering. For each process state the purpose, heating and cooling cycle, and typical microstructural changes and applications.

    Heat treatment fundamentals covering annealing, hardening, tempering and normalizing — high-value theory topic frequently examined.

  11. Unit 57 Marks Medium Priority

    Describe the principles of electroplating and anodizing. Compare the two processes in terms of purpose, mechanism, typical coatings and applications.

    Surface engineering essentials: electroplating and anodizing are standard comparative theory questions.

  12. Unit 37 Marks High Priority

    Explain the system of limits and fits. How do you interpret the fit designation $25H7/f6$? Explain how allowance and tolerance are represented in such designation.

    Limits, fits and tolerances are core metrology topics; interpretation of standard notation is routinely asked.

  13. Unit 37 Marks Medium Priority

    Differentiate between a jig and a fixture. Describe common types of jigs and fixtures and state the advantages of using jigs and fixtures in production.

    Jigs and fixtures fundamentals: identification, comparison and advantages — common short-answer theory question.

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