Manufacturing Process (ME-305) - Important Questions

Explain the role of gating, runners (and risers) in casting and how their design influences quality, efficiency and cost-effectiveness of the final cast product.

Explain the various types of casting processes and their applications.

Describe the die casting process with sketches and compare hot-chamber and cold-chamber die casting.

Explain molding sand and discuss the different types of foundry sands and their properties.

Describe the construction of a cupola furnace with a neat sketch. Also write its application.

Explain casting defects with sketches, significance of solidification, and strategies to eliminate defects.

Analyze the properties of foundry core sands and their impact on casting quality.

Compare centrifugal casting and continuous casting 0 principles, applications, advantages, limitations and suitable materials

A cylindrical riser of $6\text{ cm}$ diameter and $6\text{ cm}$ height has to be designed for a sand-casting mould for producing a steel rectangular plate casting of $7\text{ cm} \times 10\text{ cm} \times 2\text{ cm}$ dimensions having the total solidification time of $1.36\text{ minute}$. What is the total solidification time (in minute) of the riser?

Explain the procedure of investment casting with neat sketch, what are the advantages limitations and applications of investment casting?

For a constant-volume cylindrical blind riser on a closed sand mold, derive the $h:d$ ratio that minimizes the rate of solidification and comment on the result.

Describe techniques and considerations in die casting to manage dimensional tolerances via die design, process optimization and material selection.

Explain the Thermit welding process, including chemical reactions, essential conditions for a successful weld and sketches.

Discuss electrode polarity and compare AC vs DC welding in terms of machine characteristics, weld bead geometry, penetration and overall weld outcome

Enlist common welding defects with their causes and suitable remedies to ensure high-quality welds.

Explain the different types of flames used in gas welding, their characteristics and applications.

Outline the different types of welding methods and their suitability for various materials.

Discuss the importance of flux and electrodes in electric arc welding.

Evaluate the advantages and limitations of TIG and MIG welding compared to traditional welding methods

Compare TIG vs MIG welding processes, including control mechanisms and their effect on welding speed and quality

Calculate heat input in manual metal arc welding from DC power source V-I characteristics, arc length, travel speed and efficiency

Numerical calculation of weld joint cross-sectional area in arc welding from voltage, current, efficiencies and travel speed

Explain preventive measures, including gas flow adjustment and electrode manipulation, to minimize porosity defects in gas welding.

Explain how TIG welding enables precise control, including the role of shielding gas and electrode selection

Define forging and explain the different types of forging operations/processes with sketches, theory and applications.

Explain the factors affecting pattern design and the use of cores and core boxes in pattern making.

Explain what pattern allowances are, their purpose/use, types/examples and effect on final casting.

Explain with neat sketches the construction and operation of drop forging and horizontal forging machines.

Describe the applications of forged components in automobile and aerospace industries.

Define core and explain different types of core boxes with neat sketches.

Describe the different types of patterns used in casting and their specific uses.

Analyze the role of forging machines in the production process.

Explain chills, chaplets and core prints and their applications in casting with neat sketches.

Calculate pattern dimensions from linear shrinkage allowance for given final casting dimensions.

Calculate final cube size after volumetric solidification shrinkage and solid contraction without riser.

Define shrinkage, draft, machining, distortion/camber, and shake/rapping allowances with neat sketches.

Explain the construction and working/operation of hydraulic press (and pneumatic press) in manufacturing.

Compare hot rolling vs cold rolling techniques, including process differences and effects on material properties

Explain the classification and general description of machines, mills and processes used in rolling operations.

Describe the mechanical working of metals and its significance in manufacturing.

Describe bending and drawing processes in press working with example products

Explain the concept of press working and its importance in manufacturing

Describe various press working operations and factors influencing selection of methods

Explain the various types of safety devices used in press working and their importance.

Describe the shearing process in press working and explain the factors affecting shearing force.

Explain the differences between rolling structural sections, plates, and sheets.

Explain shearing, punching, piercing, blanking and trimming operations in press working

Describe piercing, slitting and deep drawing operations on press machines

Explain the working principle, components and operations of a lathe machine with a neat sketch.

General introduction / working principles and role of milling, grinding and drilling (and related) machines in metal machining.

Define grinding and discuss dressing and truing of grinding wheels.

Explain the working principle of a planer machine with a neat sketch.

Discuss the working principle and operations of shaper and planer machines.

Numerical calculation of drilling time from diameter, thickness, speed, feed, approach and overrun.

Main applications and advantages of grinding machines in precision metal working.

Basic functionality of a drilling machine and common types of drills.

Define the main components/parts of a lathe machine and describe the basic operations performed on a lathe

What is the difference between elastic and plastic deformation.