Question Bank

UNIT I: FOUNDRY PRACTICE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

MEM-103

(i) Define the term 'manufacturing'. Provide a broad classification for existing manufacturing processes. Clearly explain the differences between the identified classes. (ii) Provide a detailed historical account for the development of machine tools. What is the basic difference between mechanization and automation? What are the basic manufacturing processes? Explain each of them briefly. Identify the six basic factors involved in all casting processes. What do you understand by the term ' pattern '? Explain with neat sketches the various types of patterns used in foundry practice. Mention their typical use. Provide a detailed classification scheme for contemporary casting techniques. What are the various materials used for making patterns? Mention their specific uses. (i) What design considerations are taken into account while making patterns? (ii) What are the various allowances given on patterns? Why are these allowances necessary? (i) What do you understand by the term 'moulding '? (ii) Explain, in brief, the four important factors in the selection of moulding sands. (i) What are the various sands used for moulding? (ii) Expand on the various characteristics that good moulding sand should posses. How are they achieved? Mention some of the moulding sand ingredients used to achieve a sound mould in sand castings. What are composite moulds? Why are they used? What are cores? Expand on the various materials used for making cores. What are some of the characteristics desirable in a dry sand core? What is the major limitation of green sand cores? What are core prints? What are chaplets? What are some of the restrictions on their use, size and chemistry? Expand on the various moulding processes used in sand casting. Explain the importance and function of gates, risers and runners in a mould. What are risers? Why is it desirable to restrict the size and use of risers? Explain the importance of Chvorinov's Rule in the context of sand casting. What are some of the design functions of a gating and feeding system? Explain with the help of neat sketches, the sand casting operation in detail. Describe the pattern colour code normally used in foundries? Explain in detail the functioning of a blast furnace / cupola for the production of pig iron used in casting. What is the difference between a blast furnace and an induction furnace? Calculate the permeability number of a sand specimen if it takes 1 minute 15 seconds to pass 2000 cm3 of air at a pressure of 6 gm/cm2 through the standard sample. What are the various defects generally found in sand castings? Explain why they occur and how they can be avoided / eliminated? Explain with the help of neat sketches the reasons for the occurrence of the following types of casting defects: (a) Cold shut (b) Misrun (c) Cold shot (d) Blow hole (e) Hot tear Expand in detail on the various categories of sand casting defects. Use neat sketches to differentiate between the various categories of defects. What are some of the cleaning and finishing operations commonly performed on castings?

UNIT II: METAL FORGING PROCESS AND HOT WORKING OF METALS 1. 2. 3. 4. 5. 6. Distinguish between hot working and cold working of steel. Describe through the help of neat sketches the following equipment used in a smithy shop: (a) Smithy's Forge (b) Anvil (c) Swage Block. Differentiate between a hand hammer and a sledge hammer through neat sketches. What operations are performed in a smithy shop? Describe each operation with suitable examples. Why are hot-rolled products normally available only in standard sizes and shapes? Why is friction between the tool and workpiece not an undesirable feature in hot rolling?

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Question Bank
7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Why might small-diameter rolls be desired when rolling thin products?

MEM-103

What are the common metals used in forging? Also identify the forging temperatures of some common forgeable metals. Explain through the help of neat sketches the following operations: (a) Upsetting Describe the drop forging operation in detail. What is the difference between open-die and impression-die drop forging? Why is open-die forging not practical for large-scale production of identical products? Why are multiple steps often required in the production of an impression-die forging? What is flashless forging? What is its major advantage? What are the advantages of a counterblow or impact forging machine? What are some of the properties desired in forging dies? Why must press forging often employ heated dies? What is upset forging? Which two hot-forming processes can convert steel skelp into pipe? Elaborate on the commonly found forging defects. What is the Mannesmann milling process? Why is the Mannesmann piercing process not capable of producing extremely long lengths of seamless tubing? For what types of products might hot drawing be used instead of cold drawing? What do you understand by metal spinning? Explain with the help of neat sketches, the shear spinning operation in detail. Differentiate clearly between shear spinning and tube spinning operations through neat sketches. What do you understand by the term 'cold drawing'? Explain through neat sketches the following drawing processes. (a) Bar and tube drawing What are the materials used for drawing dies? (b) Wire drawing (b) Bending

UNIT III: SPECIAL CASTING METHODS / INDUSTRIAL SAFETY SPECIAL CASTING METHODS: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. What are the various types of moulding machines employed in foundries? What are the advantages of using these machines in foundries? Explain the working principles of jolt machine with neat sketches How does it differ from other moulding machines? Differentiate clearly between top & bottom squeezing machines. Explain their working principle also. What is a sand slinger ? How does it differ from other moulding machines? Enumerate the different casting techniques categorized as permanent mould casting methods. Explain in brief on the identified techniques. Why are permanent moulds heated before a casting is poured? What are some of the major (a) advantages; and (b) restrictions of permanent-mould casting? Describe the shell-moulding operation in detail. What are three major advantages of the shell-moulding process? Why must moderate-to-large quantities be required to justify the shell-moulding process? Elaborate on the V-Process casting technique in detail. Use neat sketches for clarity. What are some of the attractive features of the V-process (vacuum moulding)? What is slush casting? When is it used? Describe the investment casting process in detail. Use neat sketches to elaborate your description. What are common pattern materials for investment casting? Why is investment casting moulds preheated prior to pouring? What types of metals can be investment cast? Give a step-by-step procedure for the following casting processes: (a) Lost-wax process (b) Shell moulding process Describe the die-casting process in detail. Use neat sketches for clarity. Differentiate clearly between (a) Hot-chamber die-casting; and (b) Cold-chamber die-casting processes. What are the two basic types of die-casting machines? For what metals would a hot-chamber die-casting machine be attractive? How does die-casting differ from permanent-mould casting? What types of production or product requirements would tend to favour the economical use of die casting?

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20. 21. 22. 23. 24. Why must vents be incorporated into die-casting dies? Why can sand cores not be used in die casting? What is the difference between true centrifugal and semi-centrifugal casting? Describe the centrifugal casting process in detail. Use neat sketches to elaborate your description. Differentiate clearly between semi-centrifugal casting and centrifuging in detail. Why might it be desirable to machine the inner surface of a centrifugal casting?

MEM-103

INDUSTRIAL SAFETY: 1. 2. 3. 4. 5. 6. 7. What is safety? Why it is necessary and how does it pay in the long run? What are the common sources of danger of working in factories? What are the principle methods of protection against accidents? Give a brief description of each. What are the important provisions of protection in the Indian factories act with regard to safety? What do you understand by (a) Unsafe conditions; and (b) Unsafe acts of persons working in factories? What safety precautions are taken while working in a machine shop? What do you understand by the term house keeping ? What precautions and safety measure you will take while working on: (a) Lathe (b) Shaper (c) Milling Machine (d) Drilling Machine

UNIT IV: WELDING TECHNIQUES / WOOD WORKING WELDING TECHNIQUES: 1. 2. 3. 4. 5. 6. 7. 8. Provide a detailed classification for the different contemporary welding techniques. What do you understand by gas welding? Describe in brief, the equipments required for oxy-acetylene welding. Enumerate the advantages and limitations of gas welding. Differentiate clearly between low pressure welding and high pressure welding. What care should be taken in operating this equipment? Describe through the help of suitable sketches the various types of joints made in welding. What is the electric arc method of welding? Describe the process in detail. What do you understand by the term 'polarity' as applied to arc welding? What types of electrodes are used in arc welding? What is the advantage of using coated electrodes? Write short notes on: (a) Butt Welding (b) Seam Welding (c) Spot Welding (d) Percussion Welding (e) Splash Welding (f) Projection Welding (e) Filler Rods (f) Electrodes (g) Fluxes 9. Explain briefly the following types of flames: (a) Neutral Flame (b) Carburising Flame and (c) Oxidizing Flame WOOD / WOOD WORKING: 1. 2. 3. What are the properties of soft and hard wood? Explain with the examples the extant Indian varieties of wood. What do you mean by seasoning of wood? What are the different methods of seasoning? What are the advantages of wood seasoning? What are the different types of sawing methods for timber out of a log of wood? What is the effect of sawing on quality and seasoning of wood?

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4. 5. 6. 7. 8. 9. 10. 11. How is wood preserved? Explain the recent trends and chemicals used for wood preservation.

MEM-103

Enumerate the different types of joints used in carpentry work, together with their specific uses. Which of these joints are more commonly used in wooden frame work? Use sketches to support your answers. Design a wooden stool for use in masonry work. Indicate the type of joints used, together with the processes used in making them. What are the different methods of applying wood preservatives? What are the different types of glues available in the market? Where do you apply such glues in joinery work? What are the common defects in timber? Describe the various methods employed in preserving timber for increasing its durability? What is the object of painting wood? What is the effect of paint upon wood? Describe briefly, through neat sketches, the following: (a) Mallet (b) Claw Hammer (c) Rasp (d) Pincer (e) Tenon Saw (f) Dovetail Saw

12.

Describe through neat sketches, the following joints used in a carpentry shop: (a) Mortise & Tenon joint (b) Mitre joint (c) Dovetail joint

13. 14. 15. 16.

What are the various measuring tools used in carpentry shop? What is plywood? Describe how it is manufactured. over ordinary timber? State the advantages of plywood as a structural material

What are the differences between ply boards, compressed boards, and straw-boards commercially available in the market in the form of artificial wood? Explain their field of application in daily life. What types of paints are available for wooden structures? Which of these is most suitable for exposed structures?

UNIT V: MACHINE TOOLS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. What do you understand by (a) cutting tools; (b) hand tools; and (c) machine tools? Explain with examples. Differentiate clearly between attachments and accessories in the context of machine tools. What are the basic units of a machine tool? What do you understand by turning ? How does a lathe perform this operation? Explain with the help of a simple sketch the constructional details of a lathe machine (shaper / planer / drill)? What a r e the different operations that can be performed on a lathe? Support your answer with simple sketches. What specifications need to be mentioned when purchasing a lathe machine (shaper / planer / drill)? What are the different types of lathes used in the metal working industry? Identify the common applications for each of these lathe types. What is the function of (a) rake angles; and (b) clearance angles in a single point cutting tool? What is the function of a lead screw on a lathe machine? How is taper turning accomplished on a lathe? Describe (using neat sketches) some of the standard attachments used on a lathe. Explain the advantages / limitations of producing threads by forming vs. cutting. A 6.5 inch, 0.5 inch diameter stainless steel rod is being reduced to 0.480 inches by turning on a lathe. The spindle rotates at N = 400 rpm, and the tool is traveling at an axial speed of 8 inch/min. Calculate the cutting speed, feed, material removal rate, and cutting time required. [50 ft/min; 0.02 in./rev; 0.123 in.3/min; 0.75 min.] Describe the cutting tool geometry of a twist drill through a neat sketch. What operations can be performed on a drill press but not on a lathe? Explain how gun drills remain centered. Also, why is there a hollow channel in a gun drill? Why are coolants required in metal cutting? What is the effect of a coolant on surface finish? If a V-Block is to be shaped on the shaper, show how will the tool head be set?

13. 14. 15. 16. 17.

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