Mody Institute of Technology and Science, Lakshmangarh

Faculty of Engineering and Technology

End Term Examination, Autumn Semester 2013-14
B.Tech. (ME Branch III Year)
Course Name: Metal Forming, Fabrication and Casting Weight: 50%
Course Code: ME 301 Max. Marks: 100
Total No. Of Printed Pages: 3 Time: 3 Hr.
Note: First question is compulsory. Attempt any five out of remaining seven questions.

Q.1 Select the correct answer: [2*10=20]

(i.) In a gating system, the ratio 1 : 2 : 4 represents
a) sprue base area : runner area : ingate area
b) pouring basin area : ingate area : runner area
c) sprue base area : ingate area : casting area
d) runner area : ingate area : casting area
(ii.) Hardness of green sand mould increases with
a) increase in moisture content beyond 6 percent
b) increase in permeability
c) decrease in permeability
d) increase in both moisture content and permeability
(iii.) Misrun is a casting defect which occurs due to
a) very high pouring temperature of the metal
b) insufficient fluidity of the molten metal
c) absorption of gases by the liquid metal
d) improper alignment of the mould flasks
(iv.) An expendable pattern is used in
a) slush casting b) squeeze casting
c) centrifugal casting d) investment casting
(v.) Which one of the following is a solid state joining process?
a) gas tungsten arc welding b) resistance spot welding
c) friction welding d) submerged arc welding
(vi.) Shearing , slitting and bending are :
a) Forming operation b) Drawing operation
c) Press- working operation d) None of these
(vii.) Two plates of the same metal having equal thickness are to be butt welded with electric
arc. When the plate thickness changes, welding is achieved by
a) adjusting the current b) adjusting the duration of current
c) changing the electrode size d) changing the electrode coating
(viii.) Tip of the electrodes used in spot welding are made of:
a) Soft Iron b) Mild steel
c) Copper d) Aluminum
(ix.) Match the following metal forming processes with their associated stresses in the
workpiece:
Metal forming process Types of stress
1. Coining P. Tensile
2. Wire Drawing Q. Shear
3. Blanking R. Tensile and compressive
4. Deep Drawing S. Compressive

a) 1-S, 2-P, 3-Q, 4-R b) 1-S, 2-P, 3-R, 4-Q
c) 1-P, 2-Q, 3-S, 4-R d) 1-P, 2-R, 3-Q, 4-S
(x.) The maximum possible draft in cold rolling of sheet increases with the
a) increase in coefficient of friction
b) decrease in coefficient of friction
c) decrease in roll radius
d) increase in roll velocity

Q.2 a) Explain (1) Flow Stress, (2) Elastic and plastic deformation, (3) Yield criteria;
explain the advantages and limitations of Tresca criterion over Von Mises yield
criterion.
b) In a single pass rolling operation, a 20 mm thick plate with plate width of 100 mm,
is reduced to 18 mm. The roller radius is 250 mm and rotational speed is 10 rpm. The
average flow stress for the plate material is 300 MPa. [8+8]

Q.3 a) Write the operation and principal of forging process. Explain open and closed
die forging processes.
b) Explain hydrostatic extrusion. Write its merits and demerits.
c) A brass billet is to be extruded from its initial diameter of 50 mm. The working
temperature of 700 C and the extrusion constant is 250 MPa. Calculate the force
required for extrusion. [6+4+6]

Q.4 a) What is laser beam welding? Describe its main equipment, procedure, advantages,
disadvantages and application along with a neat sketch.
b) Classify the resistance welding. Write the advantages of it over other welding
processes. [8+8]

Q.5 a) Describe upset-butt, flash butt, spot, projection and percussion welding briefly with
sketches.
b) What is the purpose of pre and post heat treatment in welding operation.
c) Spot welding of two 1mm thick sheets of steel (density = 8000 kg /m
3
) is carried out
successfully by passing a certain amount of current for 0.1 second through the
electrodes. The resultant weld nugget formed is 5mm in diameter and 1.5 mm thick.
If the latent heat of fusion of steel is 1400 kJ/ kg and the effective resistance in the
welding operation is 200mW, the current passing through the electrodes is
approximately. [6+4+6]
Q.6 a) What are the common defects of casting? State their causes and remedies.
b) A 200 mm long down sprue (see fig. no. 1) has an area of cross-section of 650 mm
2

where the pouring basin meets the down sprue (i.e. at the beginning of the down sprue).
A constant head of molten metal is maintained by the pouring basin. The molten metal
flow rate is 6.5 X 10
3
mm
3
/s. Considering the end of down sprue to be open to
atmosphere and an acceleration due to gravity of 10
4
mm/s
2
, calculate the area of the
down sprue in mm
2
at its end (avoiding aspiration effect).


Figure 1
[8+8]

Q.7 a) What is AFS fineness number? Explain with a neat sketch how to determine the grain
fineness of foundry sand.
b) With a neat sketch explain the working of Jolt-Squeeze moulding machine.
c) What binders are used in shell molding? How do they confer strength? [6+6+4]

Q.8 Write short notes on the following:
a) Centrifugal casting
b) Submerged arc welding
c) Spring back in sheet metal
d) Joint preparation in welding [4x4=16]