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UNIT-I
CASTING
1. What is foundry?
Foundry is the process of forming metallic products by melting the metal, pouring
in to a cavity known as the mould.
2. What are the stages of casting process?
1. Mould making
2. lamping
!. "ouring
#. cooling
$. removal
%. trimming
!. What are the different types of pattern?
1. &ingle piece pattern
2. split pattern
!. match plate pattern
#. cope and drag pattern
$. gated pattern
%. loose piece pattern
'. sweep pattern skeleton pattern
(. segmental pattern
). &hell pattern
#. What are the properties of moulding sand?
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a. grain si*e and shape
b. porosity
c. refractoriness
d. strength
e. plasticity
$. What are the important methods of sand testing?
+ Moisture content test
+ lay content test
+ rain fitness test
+ &trength test
%. What are the steps involved in refractoriness test?
+ heating the specimen at 1$--o for 2 hours
+ observe the changers in dimension and appearance
+ if the sand is good, it retain specimen share and show very littleepansion. /f the sand is poor, specimen will shrink and distort.
'. What are the pattern materials used?
+ Wood and wood materials
+ Metal and alloy
+ "lasters
+ "lastic and rubber
+ Waes.
(. What are the various types of pattern allowance?
0i &hrinkage allowance
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0ii Machining allowance
0iii aper allowance
0iv &hake and distortion allowance
). What are the basic steps in core making process?
0i core sand preparation
0ii core making
0iii core baking
0iv core finishing
1-. What is mean by core?
3 core is a part used in casting and moulding processes to produce internal cavity
and reentrant angles.
11. 4ame the three types of core binders?
0i hermoplastic binders
0ii hermosetting binders0iii ore oils
0iv lays
12. What are the types of cores?
0i reen sand cores
0ii 5ry sand cores
0iii 6il bonded cores
0iv 7esin bonded cores
0v &odium silicate and 62 cores
1!. What are the tools used in moulding process?
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0i &hovel
0ii 7iddle
iii 7ammer
0iv &trike8off bar
0v 9ent wire
0vi :ifter
0vii rowel
0viii &wab
1#. What are the types of moulding processes?
0i reen sand moulding
0ii 5ry sand moulding
0iii :oam moulding
0iv Metal moulds
0v ;ench moulding0vi Floor moulding
0vii &weep moulding
1$.
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0ii >olt machine
0iii >olt s=uee*e machine
0iv &and slinger
1%. 4ame the different *ones in upola furnace?
0i ombustion or oidi*ing *one
0ii 7educing *one
0iii Melting *one
0iv "reneating *one
0v &tack
1'. What are the advantages of special casting process over sand casting
processes?
0i greater dimensional accuracy
0ii higher metallurgical =uality
0iii lower production cost
0iv high production rate
1%. What are the three types of centrifugal casting?
0i true centrifugal casting
0ii semi centrifugal casting
0iii centrifuge casting
1'. What are the advantages of ceramic mould casting?
0i high production rate are possible
0ii no cores are needed
0iii comple shapes can caste
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0iv machining can be eliminated
0v long lead time are needed
0vi to develop new casting
1(. What are the defects in casting processes?
0i 5irt
0ii "orosity
0iii ;low
0iv 5ross
0v &cab
0vi as hole
0vii &car
0viii /nclusion
0i ;lister
0 pinholesUNIT-II
WELDING
1. 5efine welding.
Welding is a materials oining process in which two or more parts are oined
together.
2. What are the types of welding processes?
0i 6yfuel gas welding
0ii 3rc welding
0iii 7esistance welding
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0iv &olid state welding
0v @ni=ue welding
!. 4ame the e=uipments used in gas welding?
0i oygen gas cylinder
0ii acetylene gas cylinder
0iii oygen pressure regulator
0iv acetylene pressure regulator
0v oygen gas hose 0blue
0vi acetylene gas hose 0red
0vii welding torch
0viii filler rod and flues.
#. 4ame the e=uipment used in arc welding
0i 3rc welding power source
0ii welding cables0iii electrode holder
0iv welding electrode
0v welding helmets and shields
$. What are the advantages of submerged arc welding?
a. ;ecause of thigh heat concentration, considerably higher welding speed
can be used.
b.
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"lasma arc welding in an arc welding processes wherein coalescence is produced
by the heat obtained from a constructed arc setup between a tungstenAalloy
tungsten
electrode and water cooled no**le or between a tungsten alloy tungsten electrode
and the ob.
'. What are the disadvantages of plasma arc welding?
a. Welders need ear plug because of unpleasant, disturbing and damaging noise.
b. More chances of electrical ha*ards are associated with this process.
(. What are the procedures followed in hermit welding?
a. clean the oint
b. allow the concentration
c. construct the mould
d. preheating the mould
e. crucible and its charging
). What are the e=uipments used in electron beam welding?
a. 3n electron beam gun with a high voltage power supply and controls
b. a vacuum pumping system
c. mechanical tooling fitures
d. a beam alignment system
1-. What are the disadvantages of electron beam welding?
0i /nitial cost of e=uipment is high and portable e=uipment is rare
0iiWork is to be manipulated through vacuum seals.
0iiiime and e=uipment is re=uired to create vacuum very time a new ob
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is to be welded.
0iv "recaution are needed to prevent damage from B8rays
11. What is meant by friction welding?
Friction welding is a solid state welding process wherein coalescence is produced
by the
heat obtained from mechanically induced sliding motion between rubbing surfaces.
12. 5efine 5iffusion bonding.
5iffusion bonding is a solid state process wherein coalescence of the faying
surfaces is
produced by the application of pressure and elevated temperature to carefully
cleaned and
mated metal surfaces so that they actually grow together by atomic diffusion.
1!. What are the defects in welds?
a. cracks
b. distortion
c. incomplete penetration
d. inclusions
e. porosity and blow holes
f. poor fusion
1#. 5efine ;ra*ing.
;ra*ing is a oining process in which a filer metal is melted and distributed by
capillary
action between the faying surfaces of the metal parts being oined.
1$. What are the characteristics features of filler metals and flues?
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a. melting temperature must be compatible with base metal.
b. low surface tension in li=uid phase for good wettability
c. high fluidity for penetration into the interface.
1%. What are the methods involved in bra*ing?
0i orch bra*ing
0ii Furnace bra*ing
0iii /nduction bra*ing
0iv 7esistance bra*ing
0v 5ip bra*ing
0vi /nfrared bra*ing
1'. 5efine soldering?
&oldering is similar to bra*ing and can be defined as a oining process in which a
filler
metal with melting point not eceeding #$-o is melted and distributed by
capillary action
between the faying surfaces of the metal parts being oined.
1(. What are the advantages of soldering?
i low energy input relative to bra*ing and fusion welding
ii variety of heating methods available
iii good electrical and thermal conductivity in the oint
iv easy to repair and rework
1). What is adhesive bonding?
3dhesive bonding is a oining process in which a filler material is used to hold two
or
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more closely spaced parts together by surface attachment. he filler material that
binds the
parts together is the adhesive.
2-. What are the advantages of adhesive bonding technology?
a. he adherents are not affected by heat
b. @niform stress distribution
c. "ossibility to oin large surfaces.
d. "ossibility to oin different materials
e. as proof and li=uid tigh.
UNIT-III
MACHINING
1, 5efine cold working of metals?
hose process, which are working below the recrystalli*ation temperature, are
called cold
working of metals
2, 5efine the process of mechanical working of metal?
Mechanical working process are based on permanent changes in the shape of body
due to
some etreme forces
!, ive some eamples for mechanical working of metal?
7olling Forging
Ctrusion 5rawing "ress working
#, 5efine hot working of metals,
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hose process which are working above the recrystali*ation temperature is known
as hot
working of metals
$, 3dvantages of cold working over hot working
ood surface finish
;etter dimensional accuracy
%, lassifications of rolling mills
wo high rolling mill hree high rolling mill
Four high rolling mill Multi high rolling mill
@niversal high rolling mill
', 3dvantages of cold rolling
/mproves mach inability
/mprover physical properties
ood surface finish and high accuracy
(, 5efine forging
Mechanical working of metals by which metals and alloys are elastically deformed
by the
application of compressive force is known as forging process
), lassification of forging process
6pen8die process lose8die process
1-, &ome hand tools , which is used in the forging operation
&wage block hisels Fillers
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11, ypes of force weld
:ap weld ;utt weld or ump weld 9 finished weld
12, 5efine etrusion process
/t is defined as the ratio of the cross sectional area of the billet to the cross section
area of
the product
1!, What is meant by cold and hot spinning process
old spinning process is the operation of shaping very thin metal by pressing
against ;rass
wheel
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Ctrusion "iercing.
1), 5efine forge ability
/t is defined as utility of a materials to deform before cracks appear on the metal
2-, 5efects in rolling parts
&urface defects /nternal structure depicts :amination
UNIT-IV
FORMING AND SHAPING OF PLASTICS
1. 5efine plastics.
Materials that can be reshaped 0remolded by applying heat and pressure. Most
plastics are
made from synthetic resins 0polymers through the industrial process of
polymeri*ation. wo
main types of plastics are thermoplastics and thermosets.
2. Write types of plastics.
hermoset8
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hermal /nsulation
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Mold pieces 0define the geometry of the part, and sprue, gates, runners, vents,
eection pins,
cooling system.
'. 5efine compression moulding.
he process of molding a material in a confined shape by applying pressure and
usually heat.
(. 5efine transfer moulding.
3 process of forming articles by fusing a plastic material in a chamber then forcing
the whole
mass into a hot mold to solidify.
). What are the advantages of compression moulding?
+ :ittle waste 0no gates, sprues, or runners in many molds
+ :ower tooling cost than inection molding
+ ood surface finish
+ :ess damage to fibers
+ "rocess may be automated or hand8operated
+ Material flow is short, less chance of disturbing inserts, causing product stress,
andAor eroding
molds.
1-. What are the disadvantages of compression moulding?
+
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11. 5efine cold moulding.
harge is pressed into shape while cold then cured in an oven. Cconomical but
usually poor
surface finish.
12. 5efine etrusion process.
Ctrusion is the process of s=uee*ing metal in a closed cavity through a tool,
known as a die
using either a mechanical or hydraulic press.
1!. 5efine rotational moulding.
@sed to form hollow seamless products such as bins. Molten charge is rotated in a
mold in two
perpendicular aes simultaneously, or rotated while tilting.
1#. 5efine foam moulding.
Foaming agent is combined with the charge to release gas, or air is blown into
miture while
forming.
@sed to make foams. 3mount of gas determines the density.
1$. 5efine vaccum forming.
/t is accomplished by heating the plastic sheet until it is pliable enough to be
vacuumed either
into a female mold or over a male mold.
1%. 5efine spinning.
Modified form of etrusion in which very thin fibers or yarns are produced is
called spinning.
1'. 5efine calendaring.
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Molten plastic forced between two counter8rotating rolls to produce very thin
sheets e.g.
polyethylene sheets.
1(. 5efine rotational moulding.
@sed to form hollow seamless products such as bins. Molten charge is rotated in a
mold in two
perpendicular aes simultaneously, or rotated while tilting.
1). 5efine thermoforming.
&heet material heated to working temperature then formed into desired shape by
vacuum
suction or pressure.
2-. Cplain various plastics used for blow moulding.
+
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2. 9arious sheet metal that can be formed in press working
Funnels bends boes pipe covers etc.
!. What are the various measuring tools used in sheet metal operations
&teels rule, folding rule, circumference rule, vernier calipes, micrometer, thickness
gauge and
steel metal gauge
#. What is mean by clearance
learance is the intentional space between the punch cutting edge and the die
cutting depends
on the type cutting operation the space between punch and die is provided known
us clearance
$. Mention the effect of insufficient clearance,
/t does not allow a clean break but partial break occurs. /t is also called as
secondary shear.
%. What is meant by seaming?
he process of providing lock between the two edges of the different work metal is
called
seaming.
'.
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&pring back is beyond as the movement of the metal to resume its original position
causing a
decrease in bend angle after the applied force is withdrawn.
1-. &tate the methods of stretch forming process
1. Form8block method
2. Mating8die method
11. What are the advantages of stretched forming operations?
1. ;lanks can be stretched in a single operation
2. 4o need of any heat8treatments before and after the stretching process.
!. &pring back is reduced or eliminated when compared to other forming methods
#. 5irect bending is not introduced
12. :ist out the applications of stretch forming operations.
1. "roduction of aircraft wing and fuselage parts.2. "roduction of contoured panels
for truck
trailer and bus bodies in automobile industry.
1!. Mention the various materials used for making dies and form blocks in stretch
forming
process.
Wood, masonite, *inc alloys and cast iron.
1#. &tate the law of process of fracturing in formability.
he ductility of the same material is lower if the section si*e is larger.
1$. &tate the law of geometrical similitude.
1. ;lanks are geometrically similar in all aspects with respect to another blank such
as
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dimension, thickness, width, length etc. hese geometrically similar blanks should
be
fabricated by using similar tools.
2. @nit strains at corresponding locations are identical for geometrically similar
blanks.
!. he forces re=uired to form any re=uired shape on geometrically similar blanks
are directly
proportional to the s=uare of the thickness.
#. he consumption of work for forming the re=uired shape is also proportional to
the cube of
its thickness for geometrically similar blanks.
1%. What are the formability test methods?
1. Formability tests for bulk deformation.
2. Formability test for elastic8plastic deformation and
!. &imulative tests for forming operation
#. Full scale forming tests
1'.
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1(. Mention the various types of simulative tests carried out for various cup
forming process.
1. Crichson test
2. 6lsen test
!. &urift test
#. Fukui test
1). What are the applications of forming limit diagram?
1. he new of tools in easy, hard or impossible to work be easily determined
2. ood materials used n forming operations are identified.
!. :ocation of source of trouble is also easy from a reference pressing by the
designer.
2-.