ME-305 Manufacturing Process - Jun 2025 Question Paper

Under each question, How to answer lists the points an answer should cover, outlined by CampusPrep from the syllabus. Check the details against your textbook.

1. 7 Marks
   aDiscuss the various types of casting processes and their applications.
   How to answer

   • Overview/classification of casting processes (sand, die, centrifugal, investment, shell moulding)
   • Key operational principles of primary types
   • Specific industrial applications for each casting method
   • Advantages and limitations of each process
2. 7 Marks
   bExplain the role of gating, runners, and risers in casting and how they influence the quality of the final cast product.
   How to answer

   • Functions of gating components: pouring basin, sprue, runner, and gates
   • Purpose of risers: feeding shrinkage, establishing directional solidification
   • Influence of gating/riser design on casting defects (turbulent flow, air aspiration, shrinkage cavities)
   • Schematic diagram of a complete gating system
3. 7 Marks
   aDescribe the mechanical working of metals and its significance in manufacturing.
   How to answer

   • Definition of mechanical working/metal forming through plastic deformation
   • Classification into hot working and cold working relative to recrystallization temperature
   • Significance in manufacturing (grain refinement, directional properties, elimination of voids, improved mechanical strength)
4. 7 Marks
   bCompare and contrast hot and cold rolling techniques and their impact on material properties.
   How to answer

   • Tabulated comparison between hot rolling and cold rolling (temperature, forces, tooling, tolerances)
   • Impact on material properties: hot rolling produces isotropic, refined grain structure without strain hardening; cold rolling increases yield strength and hardness via strain hardening with reduced ductility
   • Surface finish, dimensional accuracy differences and practical examples
5. 7 Marks
   aOutline the different types of welding methods and their suitability for various materials.
   How to answer

   • Broad classification of welding methods (fusion welding, solid state welding, pressure welding)
   • Overview of key types: SMAW, TIG (GTAW), MIG (GMAW), Oxy-fuel, Resistance welding
   • Suitability matrix for materials: mild steel, stainless steel, aluminum, copper alloys
   • Selection criteria based on thickness and material compatibility
6. 7 Marks
   bDiscuss the importance of flux and electrodes in electric arc welding.
   How to answer

   • Role and functions of flux (shielding against atmospheric contamination, arc stabilization, deoxidation, slag formation, alloying addition)
   • Functions of electrodes: arc initiation and conduction, supplying filler metal
   • Types of electrodes (coated/bare, consumable/non-consumable)
   • Contribution of electrode coatings to weld pool quality
7. 7 Marks
   aExplain the concept of pattern allowances in casting and their impact on the final product.
   How to answer

   • Definition and purpose of pattern allowances in sand casting
   • Why pattern dimensions differ from the final casting dimensions
   • Types of allowances: shrinkage/contraction, draft/taper, machining/finish, distortion/camber, shake/rapping
   • Impact on dimensional accuracy, surface quality, and avoidance of rejection
8. 7 Marks
   bProvide examples of different pattern allowances and their applications.
   How to answer

   • Liquid/solid shrinkage values with examples for cast iron, steel, brass, and aluminum
   • Draft allowance: taper angles (1° to 3°) for internal and external surfaces
   • Machining allowance values based on casting size and metal type
   • Distortion allowance example for U-shaped or asymmetrical castings
   • Rapping allowance consideration (negative allowance)
9. 7 Marks
   aDescribe the theory and application of forging processes.
   How to answer

   • Underlying theory: compressive deformation, recrystallization, continuous grain flow
   • Major forging techniques: open-die, closed-die (impression-die), upset forging, roll forging
   • Improvement of mechanical properties through fiber flow lines
   • Typical engineering applications: crankshafts, connecting rods, gears, turbine disks
10. 7 Marks
    bDiscuss the operation of drop and horizontal forging machines.
    How to answer

    • Working mechanism of drop forging hammers (gravity vs. steam/air drop hammers)
    • Components: anvil, ram, tup, dies, and energy delivery
    • Working principle of horizontal forging machines (upsetters) with gripping and heading dies
    • Comparison of impact versus progressive deformation and typical components produced
11. 7 Marks
    aExplain the concept of 'press working' and its importance in manufacturing.
    How to answer

    • Definition of press working (cold working of sheet metal using presses and dies)
    • Basic elements of a press working setup (punch, die, ram, bolster plate)
    • Importance: high production rates, low cost per piece in mass production, dimensional accuracy, minimal material wastage
12. 7 Marks
    bDescribe the various operations involved in press working and the factors influencing the selection of methods.
    How to answer

    • Classification into cutting/shearing operations (blanking, punching/piercing, trimming, notching, slitting)
    • Forming operations (bending, drawing, squeezing, coining, embossing)
    • Factors affecting selection: sheet material and thickness, production volume, component geometry and tolerances, press capacity available
13. 7 Marks
    aDiscuss the general description of machines and processes used in rolling operations.
    How to answer

    • Principle of rolling: passing ingot/slab between rotating rolls
    • Types of rolling mills: two-high (reversing and non-reversing), three-high, four-high, cluster mill (Sendzimir), continuous/tandem mills
    • Key machine components: rolls, roll stand, bearings, drive motor, chocks
    • Schematic roll arrangement diagrams
14. 7 Marks
    bExplain the differences between rolling structural sections, plates, and sheets.
    How to answer

    • Dimensional distinctions: plates ($t > 6\text{ mm}$), sheets ($t < 6\text{ mm}$), structural shapes (I-beams, channels, angles)
    • Equipment used: flat rolls for plates/sheets vs. specially grooved/contoured roll passes for structural shapes
    • Roll pass design sequence (breakdown, roughing, intermediate, finishing) for sections
    • Surface and metallurgical requirements for each product type
15. 7 Marks
    aOutline the basics of lathe machines, including operations and components.
    How to answer

    • Basic principle: workpiece rotates while a single-point cutting tool traverses against it
    • Principal components: bed, headstock, tailstock, carriage (saddle, cross-slide, compound rest, tool post), lead screw, feed rod
    • Common lathe operations: straight turning, facing, taper turning, knurling, parting-off, thread cutting, drilling/boring
    • Block schematic of lathe machine
16. 7 Marks
    bDiscuss the working principles of shaper, planner, milling, grinding, and drilling machines.
    How to answer

    • Shaper: reciprocating single-point tool with intermittent work feed during return stroke (quick return mechanism)
    • Planer: reciprocating heavy workpiece past stationary single-point tool(s)
    • Milling: rotating multi-point cutter with linear feed of workpiece (up/down milling)
    • Grinding: abrasive wheel rotating at high speed for micro-chip material removal and finishing
    • Drilling: rotating and axially feeding multi-point tool (twist drill) to produce cylindrical holes