ME8351 MANUFACTURING TECHNOLOGY – I L T P C

3 0 0 3
OBJECTIVE:
To introduce the concepts of basic manufacturing processes and
fabrication techniques, such as metal casting, metal joining, metal
forming and manufacture of plastic components.

UNIT I METALCASTINGPROCESSES 9
Sand Casting : Sand Mould – Type of patterns - Pattern Materials – Pattern allowances
– Moulding sand Properties and testing – Cores –Types and applications –
Moulding machines– Types and applications; Melting furnaces Blast and
Cupola Furnaces; Principle of special casting processes : Shell - investment –
Ceramic mould – Pressure die casting - Centrifugal Casting - CO2 process – Stir
casting; Defects in Sand casting

UNIT II JOINING PROCESSES 9

Operating principle, basic equipment, merits and of: Fusion welding
processes: Gas welding - Types – Flame characteristics; Manual metal arc welding –
Gas Tungsten arc welding - Gas metal arc welding – Submerged arc welding –
Electro slag welding; Operating principle and applications of: Resistance welding -
Plasma arc welding – Thermit welding – Electron beam welding – Friction
welding and Friction Stir Welding; Brazing and soldering; Weld defects: types, causes
and cure.

UNIT II METAL FORMINGPROCESSES 9

Hot working and cold working of metals – Forging processes – Open, impression
and closed die forging – forging operations. Rolling of metals– Types of Rolling –
Flat strip rolling – shape rolling operations – Defects in rolled parts. Principle of rod
and wire drawing – Tube drawing – Principles of Extrusion – Types – Hot and Cold
extrusion.

UNIT IV SHEET METAL PROCESSES 9

Sheet metal characteristics – shearing, bending and drawing operations
– Stretch forming operations – Formability of sheet metal – Test methods –
special forming processes-Working principle and applications – Hydro forming –
Rubber pad forming – Metal spinning– Introduction of Explosive forming, magnetic
pulse forming, peen forming, Super plastic forming – Micro forming

UNIT V MANUFACTURE OF PLASTIC COMPONENTS 9

Types and characteristics of plastics – Moulding of thermoplastics – working
principles and typical applications – injection moulding – Plunger and screw
machines – Compression moulding, Transfer Moulding – Typical industrial
applications – introduction to blow moulding –Rotational moulding – Film
blowing – Extrusion – Thermoforming – Bonding of Thermoplastics.

TOTAL: 45 PERIODS
 OUTCOMES:
CO1 Explain different metal casting processes, associated defects, merits and demerits
CO2 Compare different metal joining processes.
CO3 Summarize various hot working and cold working
methods of metals. CO4 Explain various sheet metal
making processes.
CO5 Distinguish various methods of manufacturing plastic components.

TEXT BOOKS:
1. Hajra Chouldhary S.K and Hajra Choudhury. AK., "Elements of
workshop Technology", volume I and II, Media promoters and Publishers
Private Limited, Mumbai, 2008
2. Kalpakjian. S, “Manufacturing Engineering and Technology”, Pearson
Education India Edition, 2013

PART - A
Unit – I M e tal Casting Proce
sse s

1. What is draft allowance? How is it provided for patterns?

It the vertical faces of pattern are perpendicular to parting line, the edges of
mould may damaged when the pattern is removed from the sand. Hence the vertical faces
are mode taper for easy removal of pattern. This slight taper given on the vertical sides
of pattern in caused draft allowance.

2. Enumerate the characteristics of following methods of sand ramming. a)

Hand b) Jolt c) Squeeze d) Slinger

Characteristic Hand Jolt Squeeze Slinger

s

Density Not Not Not Uniform

Ramming sand unifor unifor unifor
Strength Not
m less
m moderate
m high
Predicated
Production rate less moderate fast fast
Accuracy less moderate more moderate

3. What are the common allowances provided on pattern?

The various types of pattern allowances normally given are;
1. Shrinkage allowance
2. Machining or finish allowance
3. Draft or taper allowance
4. What are the functions or riser?
The main function of the riser is to supply excess molten metal to
the solidifying casting it allows the escape of air.

5. How pattern differ from casting?

Pattern is slightly larger in size as compared to the casting. Pattern may be in
two or three pieces where as a casting is in one piece.

6. What are the tests carried out to determine the quality of casting?
Destructive test: Tensile, Impact, Hardness etc.

Non Destructive: Visual, sound, magnetic particles, dye penetration, ultrasonic etc.

7. Define foundry.
A plant where the castings are made is called a foundry.

8. Define casting.
The Process of producing metal parts by pouring molten metal in to the mould
cavity of the required shape and allowing the metal to solidify. The solidified
metal piece is called as casting.

9. Define mould.
Mould is the cavity of the required casting made in wood, metal or plastics.

10. Define pattern.

The Model of the required casting made in wood, metal or plastics.

11. Name the various pattern materials.

Wood – Teak wood, white pine etc. Metal – cast iron, brass, aluminium etc. Plaster
Plastic
Wax

12. What are the different types of patterns used in foundries?

Solid or single piece pattern, match plate pattern, split pattern, sweep pattern, skeleton
Pattern, segmental pattern, loose piece pattern, shell pattern.

13. When do you made core (or) what is function of core in moulding sand?
To provide a hollow surface or recess on the casting, the core is made.

14. What is core print and what is its purpose?

A core print is an extra projection on the pattern. It supports the core.

15. What do you understand by core setting?

Caring or heating the cores to obtain enough hardness is called as core setting.
16. What are requirements of core sand?
Permeability, refractoriness, strength collapsibility, stability.

17. Mention the specific advantages of CO2 process.

Give strength and hardness to core
Process cost is less
It saves time on heating
It can be stored for long use

18. What is the properties good moulding sand?

Porosity or permeability, plasticity or flowability, strength or
cohesiveness, adhesiveness, Refractoriness, collapsibility.

19. What are the different types of moulding sand?

Green sand, Dry sand, Synthetic sand, Loam sand, Special sand, parting sand.

20. Write the composition of good moulding sand.

Green sand:
It contains 5 to 8% water and 15 to 20% clay.

21. List out any five moulding tools.

Shovel, Riddle, Rammer, Trowel, Slick, Strike off bar, lifter

22. What are the uses of runner and riser?

Runner:
It is used to make a sprue a hole in the cope.
It receives the molten metal from the pouring basin and passes to the cavity.
Riser:
It supplies excess molten metal to the solidifying casting. It allows the escape of air.

23. What are chaplets?

Some times it is not possible to provide sufficient support for a core in the
mould being poured, if the cores are bigger in size. In such cases the core is
supported with rigid metal pieces called chaplets.

24. Mention any 2 sand mould processes

Green Sand Mould

Dry Sand Mould

25. What are the different types of furnaces used for casting?
Cupola furnace, open hearth furnace, crucible furnace, pot furnace, Electric furnace.
 PART - B

1. i. Discuss the properties of moulding sand

ii. What are the various moulding methods, explain them

2. i. Explain the working principle of investment casting

ii. Discuss the casting defects and their inspection methods

3. i. What are the pattern making allowances and briefly explain

them ii. Describe centrifugal casting process

4. i. Describe the shell moulding process

ii. Explain the ceramic moulding process and state its merits and demerits

5. i. What are the factors which govern the selection of a proper material for pattern making?

ii. What are the specific advantages of match plate patterns?

Explain how they are used for making mould

UNIT II JOINING PROCESSES

PART - A

1. What are the types of joints?

1. Permanent joint 2. Temporary joints

2. Give some example for permanent joints.

1. Riveted joint

2. Welded joint

3. Define – Welding.
Welding may be defined as the process of joining similar metals by the
application of heat, with or without application of pressure and filler material.

4. What are the advantages of welding?

1. It produces permanent joints.
2. The overall cost of the welding equipment is very low.
3. A Large number of metals can be welded.
 4. A good weld is as strong as base metal.

5. What are the types of welding process?

1. Pressure welding
2. Non-pressure welding

6. Give some example for pressure welding.

Spot welding, seam welding, lap and butt welding, projection welding.

7. Give some example for non - pressure welding.

1. Gas welding
2. Electric arc welding.

8. What is the principal of resistance welding?

The current is passes through the work pieces causes local heating
and temperature rises to fusion point. Subsequent applications of pressure result in
permanent joining of work pieces.

9. Give some example for resistance welding.

Spot welding, seam welding, butt welding, projection welding.

10. Give some example for gas welding.

1. Oxy acetylene welding
2. Oxy hydrogen welding
3. Oxy butane welding.

11. What are the types of flame used in gas welding?

1. Neutral flame
2. Oxidizing flame
3. Reduction flame.

12. What are the equipments used in gas welding?

Acetylene cylinder, gas cylinder, trolley, hose and hose fitting, pressure
regulator, Welding torch.

13. List the technique used in gas welding.

1. Left ward welding. 2. Rightward welding.

3. Vertical welding 4. Overhead welding.

14. List the power sources used in arc welding.

1. AC machine 2. DC machine
3. Transformer 4. Transformer with DC rectifier
15. What is the use of flux?
To avoid the formation of oxide and get strong perfect weld. It takes away
from the impurities present in the surface of metal.\

16. Give some example for commonly used flux materials.

Borex, sodium chloride.

17. What is electrode?

Electrode made of metallic wire called core wire, coated uniformly protective
coating called flux.

18. What are the types of electrode?

1. Bare electrode 2. Dust coated electrode

19. What are the types of welding rods?

Low carbon steel rod, mild steel rod, vanadium steel rod.

20. List the spot welding methods.

Direct, indirect, push pulls method.

21. What is seam welding?

It is the resistance welding process. The heat is produced due to
resistance against current. It is also called stitch welding.

22. Define - Electro slag welding.

It is the welding process in which metal fused together by molten slag which melt
the filler material and surface of the work to be welded.

23. What are the advantages of AC arc welding?

1. The transformer maintenance cost is less.
2. Efficiency is very high.
3. The power available is very less.

24. What is submerged arc welding?

The arc is produced between the electrode and the work piece. The arc, end of
electrode, the molten pool is submerged in the molten pool.

25. What is the use of inert gases in TIG welding?

It is used to avoid atmospheric contamination of the weld pool. The gases used in
the welding process are argon helium hydrogen.

PART – B
1. i. Distinguish between gas and arc welding ii. What are the advantages of welding?

iii. Explain percussion welding

2. i. Describe Electro slag welding

ii. Distinguish between soldering and brazing

3..i. Explain spot welding ii. Explain submerged arc welding

4. i. Explain the electron beam welding process with a neat

sketch ii. Write a brief note on “Welding defects”

5. i. Sketch the three types of Oxy-acetylene flames and state their characteristics and

applications. ii. Describe the electro-slag welding process with a neat sketch.

UNIT – III BULK DEFORM ATION PROCESSES

PART - A

1. What are the general advantages of forging as a manufacturing process?

Porosity in the materials largely eliminated
Better mechanical properties
Ability of forging to withstand unpredictable loads
Rapid duplication of the components
Wide range of forgeable metals is available

2. Define cold working of metals.

Those processes, which are working below the recrystallisation temperature, are
called cold working of metals.

3. Define hot working of metals.

Those processes which are working above the recrystallisation temperature is called
hot working of metals.

4. What are the advantages of hot working over cold working?

Hot working requires less to get necessary deformation
Brittle materials can also be hot worked.

5.What are the four major drawbacks of hot working? (May 2006)
 • As hot working is carried out at high temperatures, a
rapid oxidation orscale formation takes place on the metal
surface which leads to poor surface finish and loss of metal.
• Due to the loss of carbon from the surface of the steel piece being worked,
the surface layer loses its strength.

6. Define extrusion ratio.

It is defined as the ratio of the cross sectional area of the billet to the cross section
area
of the product.

7. Define degree of drawing.

The ratios of the difference in cross sectional area before and after drawing to the initial
Cross sectional area.
RA=1- (Do)2 /Di

8.What is wire drawing.(Nov 2008)

Drawing of metal through a small aperture die and wounding in the form of coil is
called wire drawing. The aperture is generally below 16mm diameter.
9.What is meant by deep Drawing.
It is the process of making cup shaped parts from sheet metal
blanks, where the depth of the cup is greater than that of the diameter of the cup.

10. What are the methods used for producing seam less tube?
Extrusion, piercing

11. What is the formula for percentage reduction in redrawing?

% reduction= D-d/Dx100

12. What is the difference between a bloom and a billet?

Bloom – fast break down of ingot into the size of 150mm x 150 mm to 250 mm x
300mm Billet – a reduction of bloom of 50mm x 50mm to 125mm x 125mm by hot rolling.

13. Define slab, plate, sheet, and strip.

Slab - obtained from bloom by rolling
Plate - the thickness, which is having minimum 6.35 mm
Sheet - thin partner of plate
Strip - a narrow sheet having maximum with of 6.00mm

14. Define foil, bar wire.

Foil – strip with maximum width of 300mm and maximum thickness of 1.5m.
15. Define hobbing.
It is the process of forming a very smooth, accurate polished shape on punch.

16 What is the difference between coining and embossing process?

Coining - pressing operation
Embossing - forging operations

17. What is meant by spring back?

During the bending operations, when the pressure on the metal release the
bend angle may slightly change this is called spring back.

18. What do you understand by “recrystallisation” and recrystallization temperature?

The approximate minimum temperature at which complete recrystallisation of
a cold worked metals take place within a specified time.
Recrystallization: Formation of new grain when the metal undergoes working.

19. List the different types of forging machines.

1. Forging presses
2. Forging hammers
3. Forging machine or up setter

20. What is tube piercing?(Nov 2004)

It is used to produce the seamless tube by using mandrel. It is used to
produce the pierce at the center of the ballet.

21. List the different types of rolling mills.(May 2009)

1. Two high rolling mills
2. Three high rolling mills
3. Three high rolling mills
4. Cluster rolling mills

22. What are the defects in rolled parts?

1. Pitting
2. Cold shut and laps
3. Dents
4. Cracks

23. What are the types of extrusion?

1. Direct or forward extrusions
2. Indirect or backward extrusion.

24. How are seamless tubes produced?

Seamless tubing is a popular and economical raw stock for machining because it
saves drilling and boring of parts. The piercing machine consists of two rapered
rolls, called as piercing rolls.

25. What is Sejournet process?

That extrusion process which is based both on the use of a lubricantin a
viscous condition at extrusion temperature and on a separation between the lubrication of
the chamber wall and die is called Sejournet process.

PART – B

1. Classify the types of forging machines and explain any one

2. Explain the forward and back extrusion process

3. i. Classify the types of rolling mills and sketch

them ii. List out various forging defects

4. i. Describe hydrostatic extrusion process.

ii. Compare press forging and hammer forging

5. i. Explain the tube piercing process

ii. Distinguish hot and cold extrusion process and briefly explain one in each.

UNIT – IV SHEET M ETAL PROCESSES

PART - A

1. What is punching operation ?

It is the cutting operation with the help of which various shaped holes are
produced in the sheet metal. It is similar to blanking; only the main difference is that,
the hole is the desired product and the material punched out to form a hole is considered
as a waste.

2. What is super plastic forming operation ?

Superplastic forming is a metalworking process for forming sheet metal. It works
upon the theory of superplasticity, which means that a material can elongate beyond
100% of its original size.

3 .What is press brake?

Press brake (bending brake) is an open frame press used for bending, cutting and
 forming. Generally, it handless long workpieces in the form of strips. Usually press
brake have long dies and suitable and suitable for making long straight line bends.

4 .Define hydro forming process.

Hydro - mechanical forming: In this method , the blank is placed over the
punch whose shape is similar to inner of the find workpiece.
Electro - hydraulic forming : This method involves the conversion of
electrical energy into mechanical energy in a liquid medium. Electric spark in a liquid
produces shock waves and pressures which can be used for metal forming.
5.Give the difference between punching and blanking.
Blanking : It is the cutting operation of a flat metal sheet. The article punched
out is known as blank. Blank is the required product of the operation and the metal left
behind is considered as a waste.
Punching: It is similliar to blanking; only the main difference is that, the hole is
the desired product and the material punched out to form a hole is considered as a waste.

6.How is hydro forming is similar to rubber forming ?

In both the sheet metal working processes sheet metal is pressed between a die
and rubber block.
Under pressure, the rubber and sheet metal are driven into the die
and confirm to its shape by forming the part.

7. Enumerate the various typical applications of electro magnetic forming process.

Compression and expansion of circular bar was carried out it is used
for instrument gear assembly, embossing and sizing of cups etc.

8. Name any 4 four high power explosive used in explosive forming?

Dynamite
Amatol
TNT (Tri-hitrolnene)
RDX (Cyclotrimelthylene trinitramine)

9. List out major functions which affect the performance in electromagnetic forming?
High intensity between the coils
Eddy current
Coil compression
Flux concentration

10. List out and 2 advantages of explosive forming?(May 2011)

Forming process occurs in
Small interval of time
Very high compact densities can be obtained
Mixtures of metal can be easily compacted
11. Give the applications of electro hydraulic forming?
Bulging, bending, drawing, blanking and piercing
12. What is high energy rate forming process?(Nov 2010)
It includes a number of process in which part are formed at a rapid rate by
extremely
high pressure. The energy needed for processing the material is released in a very short
time. It is called high-energy rate forming process.

13. Mention the few applications of HERF

It is used for compacting metal powder
It is used for forging and cold welding
It is also used for bending and extruding
Metal cutting process is also possible

14. Classify the high – energy rate forming process?

Explosive forming, Electro hydraulic forming, Electromagnetic forming,
Dynapak high speed forming process.

15. What are materials used for making dies in explosive forming?( May 2008)
The commonly used die materials are concrete, world, epoxy, plastics, plaster of
paris and CI, stud etc.

16. What is the principle of magnetic pulse forming?

The basic principle is that discharging of a capacitor through coil over a period of
micro seconds, the magnetic flux densities of the order of hundreds of kilogauss can
be produced.

17. What is the basic principle of dynapak machine?

There are simple in construction
Better surface finished in achieved
Better control of gain and size forging capability

18. Define – blanking.

It is used to produce the outer contour of the work piece by using presses.

19. What are the types of sheet metal joining tools?

1. Seaming tools 2. Grooving punch 3. Rivet set

20. What are the type’s characteristics of sheet metals?

1. Plasticity
2. Malleability
3. Stretch ability

21.Define Notching.
It refers to the removing pieces from the edge. In this process, the metal is
removed from the side (or) edge of a sheet to get the desired shape.
22.Define Stretch forming.(Nov 2006)

The sheet metal is placed under a tensile load over a forming block and
stretching it beyond its elastic limit and to the plastic range, thus cause
permanent set to take place.this process is useful in making prototype models of
aircraft and automotive parts.

23.Define Wrinkling
It is caused by compressive stresses in the plane of the sheet . It can be
objectionable or can be useful in imparting stiffness to parts. It can be controlled by
proper tool and die design.

24. What are the factors affecting shearing operation?

Shape and material of punch
Die,speed of punching,lubrication
Clearance between punch & die.

25. Define Embossing.

With the help of this operation, specific shapes or figures are produced on the
sheet metal.It is used for decorative purpose or giving details like names, trade marks,
specifications, etc. On the sheet metal.

PART-B

1. i. Explain any one stretch forming operation

ii. Define formability and how it is tested?

iii. What is drawing operation?

2.i. Explain the metal spinning operation

ii. Describe the magnetic pulse forming process

3.What is deep drawing operation? Explain with a neat sketch.

4. i. Explain rubber pad forming process

ii. Describe the electro hydraulic forming process

5. i. Describe the explosive forming process

ii. How are aluminium kitchen utensils produced?

UNIT V MANUFACTURING OF PLASTIC COMPONENTS

PART - A
1. Classify the types of plastics.
1. Thermoplastics
2. Thermosetting plastics.

2. Classify thermoplastics.
1. Amorphous – Methacrylate, polyvinyl chloride, cellulose, fluorinated polymer
2. Crystalline – polyethylene, polyamide, polypropylene

3. List the application of blow moulding.

It is used to produce hollow components like containers, drink bottles etc.

4. What are the characteristics of thermosetting plastics? (May 2006)

1. It cannot soften once it moulded even at high temperature.
2. These plastics have cross linked molecules
3. These links are broken at high temperature but important properties are destroyed.

5. Give some example for thermosetting plastics.

Phenol formaldehyde, urea formaldehyde, phenolic, polyester, epoxide.

6. Distinguish between thermo and thermosetting plastics.

1. They can be repeadly softened 1. Once hardened and set, they do by heat
and hardened by cooling. not soften with the application of heat.
2. They are comparatively softer 2. They are more stronger and and less strong
harder than thermoplastics
3. They are produced by the 3. They are produced by the Polymerization condensation
Polymerization
4. They are usually supplied as 4. They are usually supplied in
granular material polymerized form.

7. What are the types of injection mouldings?

1. Straight plunger type
2. Single stage reciprocating screw type
3. Two stage plunger or screw plasticizer type.

8. What is extrusion?
It is the term applied to the Process OF shaping plastics through die orifice. It
is a continuous process.

9. List the parts used in the transfer moulding.

1. Plunger
2. Sprue.
3. Knockout pins
4. Cooling systems
5. Transfer chamber.
10. What is the use of torpedo and hopper?
Hopper – It is used to feed the granular form of material in to the heated cylinder.
Torpedo – It helps in spreading the moulding material uniform around the wall of
the heated cylinder.

11. What is the use of rotational moulding?

It is used to produce the hollow component like toys. Normally it is used for
polyvinyl chloride, polyethylene.

12. What is calendaring?

It is used to produce sheets and films from plastics materials such as
polyvinyl chloride, polyethylene.

13. What is Parison? (May 11)

The blow moulding process starts with the production of a tube made of
thermoplastics material. This is called parison.

14. List the types of joining of plastics.(Nov 11)

1. Mechanical fastening
2. Solvent bonding
3. Hot plate welding
4. Induction welding.

15. Define - solvent welding.

It is used to join the plastics by the help of solvent. The solvent is used to soften
the plastics and joining by pressing together.

16. Define degree of polyenerization.

It is the number of repetitive units present in one molecule of a polymer.
Degree of polymerisation =Molecular weight of a polymer/
Molecular weight of a single monomer
17. Define - solvent welding.
It is used to join the plastics by the help of solvent. The solvent is used to
soften the plastics and joining by pressing together.

18. What is film blowing?

In this process a heated doughy paste of plastic compound is passed through a series
of hot rollers, where it is squeezed into the from of thin sheet of uniform thickness. It is
used for making plastic sheets and films.

19.What are the two types of polymerization.

1.Addition polymerization
2.Condensation polymerization

20. What is rotational mouldig of plastics?

• Rotataional moulding also called as roto-moulding.
 • A measured amount of polyemer power is placed in a thin walled metal mould
and the mould is closed.
• Then the mould is rotated about two mutually perpendicular axes as it is heated.

21. Applications of compression moulding.

1.Dishes , Handles , container caps, fittings, electrical and electronic components.

2.Scoops, spoilers, hoods, fenders.
3.Polyester fiber glass resin systems (SMC/BMC)

23. List out the material for processing of plastics?

The following mentioned are the various polymer additives used in practice:
(1) Filler material (2) Plasticizers (3) Stabilizers (4) Colorants (5) Flame retardants (6)
Reinforcements (7) Lubricants.

24.What is film blowing? (May 2007)

In this process a heated doughy paste of plastic compound is passed through a
seriesof hot rollers, where it is squeezed into the from of thin sheet of uniform thickness. It
isused for making plastic sheets and films

PART – B

1. Explain the principle of injection moulding process

2 .i. Describe any method of bonding thermoplastics

ii. What is laminating? Explain the low pressure method of laminating

3. i.Explain the transfer moulding process

ii. Why screw injection moulding machine is better than a ram type injection moulding
machine?

4. i.Describe the compression moulding process

ii. Describe briefly any two thermoplastics and thermosetting plastics

5.What are the process used for processing of thermoplastic. Explain any one
process with suitable sketches