UNIT- I METAL CASTING PROCESSES

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 Sandcasting.
PART – A

1. State any four types of patterns.

The various types of patterns which are commonly used are as follows:
 Single piece or solid pattern
 Two piece or split pattern
 Loose piece pattern
 Cope and drag pattern
 Gated pattern
2. What are chaplets?
Chaplets are supports that are provided with cores which are slender or too long to be Properly
supported in core prints.
3. Define casting.
Casting is the process of forming objects by putting molten metal in moulds and letting it solidify.
4. Mention any two advantages and disadvantages of die casting.
Advantages:
 It is a very fast process.
 Moulds have longer life.
 Better surface can be obtained.
Limitations:
 Moulds are much costlier.
 This method is not suitable for small quantity production.
 Shape and weight of the casting is limited.
5. Write the requirements of good pattern.
 Simple in design
 Cheap and readily available
 Light in mass
 Surface id smooth
 Have high strength
6. What is core venting?
While pouring the mould with molten metal mould walls and cores heat up rapidly and releases large
amount of gases. In order to prevent casting defects these gases must be vented out. For this purpose
core venting are used. Core venting is incorporated in the core box itself.
7. What function of core?
Functions of core are:
 Core provides a means of forming the main internal cavity for hollow casting.
 Core provides external undercut feature.
 Cores can be inserted to obtain deep recesses in the casting.
 Cores can be used to increase the strength of the mould.
8. Which process is called lost waxing method? Why?
Investment casting process is also known as Lost-wax process. The term investment refers to a clock
or special covering apparel. In investment casting, the clock is a refractory mould which surrounds
the pre-coated wax pattern.
 9. What is the function of core print?
 Core prints are basically extra projections provided on the pattern.
 They form core seats in the mould when pattern is embedded in the sand for mould making.
 Core seats are provided to support all the types of cores.
 Though the core prints are the part of pattern, they do not appear on the cast part.
10. What are the advantages and applications of ceramic moulds?
Advantages:
 It is less expensive
 Intricate objects can be casted.
 Castings of thin sections and which do not require machining can be produced.
Applications:
 It is mainly used for all material using better ingredient in slurry.
11. What are the pattern materials?
 Wood
 Metal
 Plastic
 Plaster
 Wax
12. Explain the term fettling.
Fettling is the name given to cover all those operations which help the casting to give a good
appearance. It includes the removal of cores, sand, gates, risers, runners and other unwanted
projections from the casting.
13. 13. Name the steps involved in making a casting.
Steps involved in making a casting are
(1) (1)Pattern making (2) Sand mixing and preparation
(3) Core making (4) Melting
(5) Pouring (6) Finishing
(7) Testing (8) Heat treatment
(9) Re-testing
14. 14. What are the applications of casting?
Transportation vehicles (in automobile engine and tractors)
Machine tool structures
Turbine vanes and power generators
Mill housing
Pump filter and valve
15. Define pattern.
A pattern is defined as a model or replica of the object to be cast.
A pattern exactly resembles the casting to be made except for the various allowances.
16. 16. List the allowances of pattern.
The following allowances are provided on the pattern :
 Shrinkage or contraction allowance
 Machining allowance
 Draft or taper allowance
 Distortion allowance
 Rapping or shake allowance
17. 17. What are the factors on which amount of machining depends?
Factors affecting machining are
 Metal of casting
 Machining method used
  Casting method used
 Shape and size of the casting
 Amount of finish required on the machined portion
18. Why is a taper allowance used?
Draft allowance or taper allowance is given to all vertical faces of a pattern for their easy.
Removal from sand without damaging the mould.
19. What is meant by grain fineness number?
A.F.S number is a number proposed by American Foundry men’s Society as a measure of the sand
texture. Sands are classified into coarse, medium or fine depending on the cumulative percentage of
sand reained on a set of sieves and pan of a sifter.
20. How do you eliminate warpage ?
To eliminate this defect, an opposite distortion is provided on the pattern, so that the effect is
balanced and correct shape of the casting is produced
21. Write the significance of loose moulding.
Some patterns embedded in the moulding sand cannot be withdrawn, hence such patterns are
made with one or more loose pieces for their easy removal from the moulding box.
22. What are the types of moulding sand?
All types of sands used in the foundry can be grouped as:
1. 1. Natural sand 2. Synthetic sand 3. Special sands
23. Why is synthetic sand better than natural sand?
 It requires less proportion of binder.
 Higher refractoriness and permeability.
 Properties can be easily controlled.
 Refractory grain size is more uniform.
24. 24. Name the different types of special sand.
 Green sand
 Loam sand
 Core sand
 Parting sand
 Facing sand
 Backing sand
24. Define permeability.
The sand must be porous to allow the gases and steam generated within the moulds to be removed
freely. This property of sand is known as permeability or porosity
25. Define Muller.
It is a mechanical mixer used for mixing sand ingredients in dry state.
26. 26. Name various methods of sand testing.
 Moisture content test
 Clay content test
 Permeability test
 Grain fineness test
27. 27. Name the factors affecting permeability test
 Grain shape and size
 Grain distribution
 Binder and its contents
 Water amount in the moulding sand
 Degree of ramming
29. Define mould and loam moulding.
When the pattern is removed, a cavity corresponding to the shape of the pattern remains in
the sand which is known as mould or mould cavity.
In this, a rough structure of component is made by hand using bricks and loam sand. The sand
used is known as loam sand or loam mortar.
 30. Explain in short shell moulding.
Shell moulding is suitable for thin walled articles.
It consists of making a mould that has two or more thin shell like parts consisting of thermosetting
resin bonded sand.
31. 31. Name defects occurring in casting.
 Blow holes
 Porosity
 Shrinkage
 Inclusions
 Hot tears or hot cracks
 Misrun and cold shuts

PART – B & C
1. How are the patterns classified? Describe any two types with sketches.
2. Enumerate the casting defects and suggest suitable remedies.
3.i) Explain the properties required for moulding sand?
ii) Explain the preparation of moulding sand process.
4.i) Explain any one type of centrifugal casting.
ii) Name any five casting defects and explain the remidies.
5. What are the pattern making allowances and briefly explain them.
6. Briefly explain the carbon dioxide CO2 moulding process and state two important merits and
demerits.
6. Explain the Centrifugal casting process.
7. List any eight casting defects, their causes and remedies.
8. Explain the Ceramic mould casting process.
9. Give the sequence of step in pressure die casting process.
10. Briefly explain the different methods for inspection of casting.
11. Describe the operation of a cupola furnace for melting cast iron.

UNIT- II JOINING PROCESSES

Operating principle, basic equipment, merits and applications 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.
PART – A
1. List out any four arc welding equipment.
The most commonly used equipments for arc welding are as follows:
 A.C or D.C. machine
 Wire brush
 Cables and connectors
 Ear thing clamps
 Chipping hammer

2. What are the special features of friction welding?

Friction welding is a solid state welding process where coalescence is produced by t he heat
obtained from mechanically induced sliding motion between rubbing surfaces.
The work parts are held together under pressure.
Its operating is simple.
Power required for the operation is low.
It is used for joining steels, super alloys, non-ferrous metals and combinations of m etals.

3. Define resistance welding process.

Resistance welding is a process where coalescence is produced by the heat obtained from
resistance offered by the workpiece to the flow of electric current in a circuit of which the work
piece is a part and by the application of pressure.
4. What is weld porosity? How is it caused?
Porosity is the formation of small holes or pores in the weld.
Porosity is caused by entrapment of gases during the solidification process
The gases so entrapped mostly consists of hydrogen, oxygen and nitrogen of which hydrogen is
most prominent for causing porosity
5. How can slag inclusions in welding be an of small voided?
Avoid multi layer welding
Reduce arc length
Increase electrode angle
Avoid using large electrode
6. How does brazing differ from braze welding?
Brazing Braze Welding

The filler alloy is fed to one or The filler alloy is deposited

more points in the assembly and it directly at the point where it is
is drawn into the rest of the desired.
joint by capillary action.

7. Why flux is coated on filler rods?

The coating improves penetration and surface finish.
Suitable coating will improve metal deposition rates.
8. What is the application of carburizing flame?
Carburizing flame is generally used for:
Welding of low alloy steel rods
 Non-ferrous metals
High carbon steel
9. What are the diameter and length of the electrodes available in the market?
Standard length of electrodes is 250 mm, 300 mm and 450 mm.
Standard diameters of electrodes are 1.6,2 ,2.5, 3.2, 4,5,6,7,8, and 9 mm.
10. Define weld ability.
Weld ability is defined as the capacity of a material to be welded under fabrication
conditions imposed in a specific and suitably designed structure and to perform satisfactorily in
the intended service.
11. State requirement of a good weldability.
A metallic material with adequate weld ability should fulfill the following requirements:
 Contribute to good weld quality even with high dilution.
 Have unchanged corrosion resistance after welding.
 Have full strength and toughness after welding.
 Should not embrittle after stress relieving.
[Link] is welding classified?
 Gas welding
 Arc welding
 Resistance welding
 Solid state welding
 Thermo-chemical welding processes
 Radiant energy welding processes
[Link] the types of flames.
The generated flames are classified into following three types
 Neutral flame (Acetylene and oxygen in equal proportion)
 Oxidizing flame (Excess of oxygen)
 Reducing flame or carburizing flame (Excess of acetylene)
13. 14. Where is oxdizing flame used?
 Copper-base metals
 Zinc-base metals
 Ferrous metals such as manganese steel, cast iron, etc.
14. 15. Explain the function of flux in welding.
While welding, if the metal is heated in air then the oxygen from air combines with the metal to
form oxides. This results in poor quality, low weld strength hence, to avoid this
difficulty a flux is employed during welding. It prevents the oxidation of molten metal.
15. 16. Give the applications of gas welding.
Gas welding is most widely used for the following purposes:
 Joining thin materials.
 Joining most ferrous and non-ferrous metals.
 In automobile and aircraft industries.
 In sheet metal fabricating plant.
17. What is arc welding?
Electric arc welding is a fusion welding process in which welding heat is obtained from an
electric arc between an electrode and the workpiece.
18. Define arc length and arc crater.
The distance between the centre of arc of the electrode tip and the bottom of arc crater is called as
arc length. A small depression is formed in the base of the metal which is called as arc crater.
19. Define SMAW.
It is an arc welding process where coalescence is produced by heating the workpiece with an
 electric arc set up between the flux coated electrode and the workpiece.
19. 20. What is submerged arc welding ?
It is an arc welding process where coalescence is produced by heating, with an electric arc
set up between bare metal electrode and workpiece.
20. 21. Explain in short plasma arc welding.
It is an arc welding process where coalescence is produced by the heat obtained from a
constricted arc set up between a tungsten electrde and the water cooled nozzle or the workpiece.
The process employs two inert gases i.e. one forms the plasma arc and the second shields the
plasma [Link] rod may or may not be added and pressure is not required for welding.
21. Write about special feature of flux cored welding.
The electrode is flux cored i.e. flux is contained within the hollow electrode. The flux cored
electrode is coiled and supplied to the arc as a continuous wire. The flux inside the wire provides
the necessary shielding of the weld pool.
22. What are the factors affecting resistance welding?
Four factors are involved in operation of resistance welding:
 Amount of current passing through the work piece.
 The pressure that electrodes transfer to the work piece.
 Time during which current flows.
 Area of electrode tip in contact with the work piece.
23. What is adhesive bonding?
Adhesive bonding is the process of joining materials by using adhesives. The term adhesive
includes substances such as glues, cements and other bonding agents.
Main steps in adhesive bonding are
(1) Surface Preparation (2) Applying the primer
(3) Applying the adhesive (4) Assembling adhesive coated components
(5) Curing the assembly (6) Testing of the joints
24. Explain thermoplastic adhesives.
Thermoplastic type adhesives soften at high temperature. They are easy to use and are employed
as, air drying dispersions, emulsions or solutions that achieve their strength through the
evaporation of the solvent
25. Explain thermosetting adhesives.
Ans: Thermosetting adhesives, once hardened cannot be remelted and a broken joint cannot be
rebounded by heating also. These types of adhesives cure or harden by chemical reactions like
polymerisation, condensation, vulcanisation or oxidation caused by the addition of a catalyst; heat,
pressure, radiations, etc.
26. What is brazing?
It is defined as a group of joining processes where coalescence is produced bu heating to a suitable
temperature and by using a filler metal having a liquidus above 4700 C and below the solids of the
base metal.
27. What is thermit welding?
Thermit welding is a fusion welding process that makes use of the intense heat produced
when a mixture containing iron oxide and powdered aluminium is ignited. It reduces iron
oxide to thermit steel and slag.
28. Name different defects in weld.
(a) Cracks (b) Distortion (c) Inclusions
(d) Porosity and blow holes (e) Undercutting (f) Overlapping
(g) Spatter (h) Poor fusion
(i) Poor weld bead appearance (j) Incomplete penetration
29. What do you mean by bronze welding?
Bronze welding does not mean the welding of bronze , but it is a welding using bronze filler rod.
PART – B & C
1. What is a soldering flux? What different types of soldering fluxes are used?
 2. i) Explain the spot welding process.
ii) Explain the Arc welding process and its positions.
3. Explain the submerged arc welding process.
4. Explain the gas (Oxy Acetylene ) welding process.
5. Explain the electron beam welding process with a neat sketch and the merits, limitations and
applications.
6. Distinguish between soldering and brazing.
7. Explain the features of neutral, reducing and oxidizing flames. Why is a reducing flame so
called?
8. Discuss the sequence of operations in friction welding.
9. What are the no destructive test used in welding inspection and also explain any two
methods.
10. Explain the TIG and MIG system of welding. Give the applications of each.
11. Explain the types of resistance welding process giving the equipment parameters controlled
and the applications.
12. Sketch the different types of weld defects and mention how they occur.

UNIT III – METAL FORMING PROCESSES

PART – A
1. 1. What are the four major drawbacks of hot working?
As hot working is carried out at high temperatures, a rapid oxidation or scale 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.
This weakening of the surface layer may give rise to fatigue crack which results in failure of the
part.
 Close tolerance cannot be obtained.
Hot working involves excessive expenditure on account of high tooling cost.
2 Classify the types of extrusion.
 Hot Extrusion
 Cold Extrusion
 Hot Extrusion
 Direct extrusion
 Indirect extrusion
 Tube extrusion
3. What is the difference between a bloom and a billet?
A bloom has a square cross section with minimum size of 150x150 mm and a billet is smaller than
bloom and it may have any square section from 38 mm upto the size of a bloom.
4 What is impact extrusion ?
The raw material is in slug form which have been turned from a bar or punched from a strip.
By using punch and dies, the operation is performed. The slug is placed in the die and struck
from top by the punch opareting at high pressure and speed
5. Why are a number of passes required to roll a steel bar?
To reduce the thickness and to increase the width of the bar number of passes is required.
6. 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.
7. What is Sojourned process?
That extrusion process which is based both on the use of a lubricant in a viscous condition at
extrusion temperature and on a separation between the lubrication of the chamber wall and die is
called Sojourned process.
8. What is skew rolling?
The rolls are powered and the work piece is in due to frictional force between metal and
surface. The torque on the rolls is being zero.
9. Explain the term Extrusion process.
Ans: The extrusion process consists of compressing a metal inside a chamber to force it out
through a small opening which is called as die. Any plastic material can be successfully extruded. A
large number of extruded shapes which are commonly used are tubes, rods, structural shapes and
lead covered cables. During the process, a heated cylindrical billet is
placed in the container and forced out through a steel die with the help of a ram or plunger.
10. What are the disadvantages of forging processes?
 Complicated shapes cannot be produced.
 Generally used for large parts.
 Because of cost of dies, process is costly.
11. What is the purpose of rolling ?
The main purpose of rolling is to convert larger sections such as ingots into smaller
sections, which can be used directly in as rolled state or stock for working through other
process.
12. 12. What are the types of rolling mills?
According to the number and arrangement of the rolls, rolling mills are classified as follows:
1. Two-high rolling mill 2. Three-high rolling mill
3. Four-high rolling mill 4. Tandem rolling mill
5. Cluster rolling mill 6. Planetary rolling mill
13. Explain cluster rolling mill.
It is a special type of four high rolling mill. In this, each of the two working rolls is backed up
by two or more of the larger back up rolls.
14. What is tandem rolling mill?
It is a set of two or three stands of rolls set in parallel alignment. This facilitates a continuous
pass through each one successively without change of direction of the metal or pause in the rolling
process.
15. What is the main function of planetary rolling mill?
The main feature of this mill is that, it reduces a hot slab to a coiled strip in a single pass.
16. Define Extrusion.
The extrusion process consists of compressing a metal inside a chamber to force it out through a
small opening which is called as die.
17. Which extrusion requires less force and define it.
As compared to direct extrusion, less total force is required in indirect extrusion.
In this type, the ram or plunger used is hollow and as it presses the billet against the backwall of the
closed chamber, the metal is extruded back into the plunger.
18. What is forging?
Forging is the process of shaping heated metal by the application of sudden blows (hammer
forging) or steady pressure (press forging) and makes use of the characteristic of plasticity of the
material.
19. How is forging classified?
According to the equipments utilized for forging, they are classified as follows:
Smith die (Open die) forging;
 Hand forging
 Power forging
Impression die (Closed die) forging:
 Drop forging
 Press forging
 Maching or upset forging
 Roll forging
20. Define smithing.
Smithing is the act or art of working on forging metals, as iron, into any required shape.
21. Define ball peen hammer.
It is most suitable hammer for hand forging operations. It has a tough cast steel or forged steel
head which is fitted to a wooden handle. Once end of the head is flat called as face i.e.
haedened and polished. It is used for general striking and hammering purpose. Another end
is half ball shaped called as peen i.e. used for riveting or burring-over purpose.

22. Define angle of bite for rolling.

Angle of bite is the angle between the entrance plane and the centre lane of the rolls
23. What is upsetting ?
It is a process through which the cross-section of a metal piece is increased with a corresponding
increase in its length.
24. What is setting down?
Setting down is the operation through which the rounding of a corner is removed, to make it square
by uaing a set hammer.
25. Explain fullering.
Fullering is also called as spreading. Fullering the metal along the length of the workpiece is
done bu working spearate sections. In this, the axis of the work piece is positoned perpendicular to
the width of the flat die.
26. Define the term extrusion ratio.
It is defined as the ratio of the cross section area of the straight billet to the final cross sectional area
of the extruded section.
27. What happens due to swaging?
By swaging, one end of a tube is reduced in diameter and passed through the die, whereas on
the other side of the die this end is gripped in tongs which are connected to the draw bench
28. What is cold forging?
Cold forging is a cold upsetting process adapted for large scale production of small cold upset parts
from a wire stock. For example, small bolts, rivets, screws, pins, nails and small machine parts,
small balls for ball bearings, etc.
29. Define swaging.
Rotary swaging is a process of reducing the cross-sectional shape of bars, rods, tubes or wires by a
large number of impacting blows with one or more pairs of opposed dies.
30. Compare hot and cold working.

S. Hot working Cold working

No.
1. Hot working is carried out above the Cold working is carried out below the
recrystallisation temperature but below therecrystallisation temperature and as such
melting point, hence deformation of metalthere is not appreciable recovery of metal.
and recovery takes place simultaneously.

2. During the process, residual stresses During the process, residual stresses are
are not developed in the metal. developed in the metal.
3. Because of higher deformation The stress required to cause deformation
temperature used, the stress required foris much higher.
deformation is less.

PART – B & C
1. (i) Classify the types of rolling mills and sketch them. May 2006,
(ii) Explain forging operations.
[Link] out the various forging defects.

3. Describe the indirect extrusion process for solid and hollow work piece and hydrostatic
extrusion
Process.
4. Explain briefly the wire drawing process.
5. Describe and specify the merits and limitations of different kinds of rolling mills.
[Link] hot working and cold working process.
7.(i) Describe the difference between a bloom, a slab and a billet.
(ii) Explain ring rolling and thread rolling processes.
8. Explain briefly with neat sketch, direct and indirect extrusion process.
9. Explain with neat sketches of upsetting and drawing down operations.
[Link] is shape rolling? Mention the products of shape rolling and explain the production of
anyone of these products with sketch.
 [Link] between open die and closed die forging.
12. Distinguish between wire drawing and tube drawing.
13.(i) Classify the types of rolling mills and sketch them.
(ii) Explain forging operations.

UNIT IV – SHEET METAL 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
[Link] 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. 4. Define hydro forming process.
Hydro forming is a process which can be carried out in two ways:
Hydro - mechanical forming
Electro - hydraulic forming
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.
[Link] the difference between punching and blaking.
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.
[Link] 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.
[Link] do you mean by minimum bend radius?
It is the radius of curvature on inside surface of the bend. If the bend radius is too small,
then cracking of a material on the outer tensile surface takes place. To prevent any damage to
punch and die, the bend radius should not be less than 0.8mm.
8. 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, tradema rks, specifications, etc. On
the sheet metal.
9. Name the operations of sheet metal working
 The main operations are as follows:
 Shearing
 Bending
 Drawing
 Forming
10. 10. Explain Shearing
It is process of cutting a straight line across a strip, sheet or bar shearing process has three
important stages;
Plastic deformation
Fracture ( Crack propagation)
Shear
Shearing is performed either by using hand or by using machines also.
[Link] Bending
The bending operation involves stretching of metal on the outer surface and compressing it on
inner surface along a neutral axis which unchanged. Sheet metal can be bent by hammering on a
base by hand or by bending machines.

12. Explain drawing

Drawing operation is used to produce thin walled hollow shapes in sheet metal. It is carried
out by using a die and punch on a press machine. If the drawn length is more than the width then
the operation is called as deep drawing.

[Link] forming
For safety purpose, the edges of the sheet metal products are formed of folded. Alse, formed
edges provide stiffness to the components so that they will not retain their shapes during
handling.
14. What is press working?
Press working is a chip less manufacturing process by which various components are produced
from sheet metal
15. Why are press machines preferred?
Press machines are preferred for mass production of similar components, because for each
component separate tool is required and the cost of every press tool is very high as compared to
the cost of other cutting tools.
16. What is the difference between manually and power operated press?
The main difference between manually operated press and power press is that, the former
moves by means of a screw and the latter by means of a crankshaft.

17. Explain press operations.

Press operations may be grouped into two categories i.e. cutting operations and forming
operations. In cutting operations, the workpiece is stressed beyond its ultimate strength
whereas; in forming operations, the stresses are below the ultimate strength of the metal.
18. Define trimming.
It is used for cutting unwanted excess material from the perphery of a previously formed
workpiece.
19. Define shaving
It is almost similar to trimming, but only small amount of material is removed during the
operation as compared to trimming
20. Define lancing
In this operation, there is a cutting of the sheet metal through a small length and bending this small
cut portion downwards
21. What is spring back?
At the end of a metal working process, when the pressure on the metal is released, there is an elastic
 recovery by the material. Due to this total deformation of metal will get reduced. This phenomenon
is called spring back.
22. What is clearance?
During metal cutting, the shape of the punch is similar to die opening except that, it is smaller
on each side. This difference in dimensions between die and punch(making members of a die
set) is known as clearance.
23. Why is angular clearance provided?
Angular clearance is provided to enable the blank to clear the die easily and fall freely out of
the die block. If the angular clearance is not provided, the punched blank would remain stuck in the
die block.
24. What is tonnage capacity?
The tonnage capacity of a mechanical press is calculated by,
Tonnage capacity = Shear strength of a crankshaft material x Area of crankshaft bearings.
The tonnage capacity of a hydraulic press is calculated by, Tonnage capacity = Piston area x Oil
pressure in the cylinder.
25. What is die space and press adjustment?
Die space: The available surface for mounting the die and punch components in the press. Press
adjustment: The distance through which the ram can be lowered below its shut height position.
26. Define penetration.
The distance which the punch enters into the stock to cause rupture is called as penetration,
and generally it is given in terms of the percentage of the stock thickness. The percentage
penetration depends on the mateial being cut and thickness of the material.
27. Explain bend radius.
It is the radius of curvature on inside of the bend. If the bend radius is too small, then cracking of
a material on the outer tensile surface takes place. To prevent any damage to punch and die, the
bend radius should do not be less than 0.8mm.
[Link] formability.
Formability represents the response and suitability of the material for forming processes.
29. What is process of fracturing?
It states that, ductility of the metal is lower if its section size is larger.
It refers to identical metal from which specimens of different section thickness have been
machined and tested.
30. 30. What is explosive forming and how is it classified?
Explosive forming makes use of the pressure wave generated by an explosion in a fluid, for
applying the pressure against the wall of the die. The explosives are used in the form of rod, sheet,
granules, stick, liquid, etc. According to the placement of the explosive (charge) the operations are
divided in two categoies:
i. Stand off operation ii. Contact operation.
PART B & C
1. Explain principle of magnetic pulse forming?
2. Describe the electro hydraulic process?
3. What is drawing operation? Explain with neat sketch.
4. Describe the various test methods used in sheet metal forming.
5. Explain as details the working principles and applications of any two special forming.
6. Explain the super plastic forming process.
7. (i) Explain the rubber pad forming?
(ii) Discuss the characteristics of metal and its importance to sheet metal forming.
8. Name and describe the common bending operation.
9. What is an explosive forming? Explain with the sketches?
10. (i) Write short notes on hydro forming.
(ii) (ii)Explain with a neat sketch the principle of stretch forming.
11. Explain the principle of metal spinning process.

UNIT V – MANUFACTURE OF PLASTIC COMPONENTS

PART – A
1. What are the characteristic of thermoplastics ?
Themoplastics polymers soften when heated and harden, when [Link] types of
polymers are soft and ductile. They have low melting temperature and can be repeatedly
moulded and remoulded to the required shapes.
2. 2. List out the material for processing of plastics?
The following mentioned are the various polymer additives used in practice:
 Filler material
 Plasticizers
 Stabilizers
 Colorants
 Flame retardants
 Reinforcements
 Lubricants
3. List the advantage of cold forming of plastics?
Cold forming can be carried out at room temperature
It is used to produce filament and fibres
It is a simple process.
4. 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.
5. What are the types of plastics?
Polymers are classified in two major categories:
 Thermoplastic polymers (Soften when heated and harden when cooled)
 Thermosetting polymers (Soften when heated and permanently hardened when
cooled).
6. What is compression moulding?
The main objective is to melt the material due to compression.
7 Name the parts made by rotational moulding.
Rotational moulding process is mostly used for the production of toys in P.V.C like horse,
boats, etc. Larger containers upto 20 m3 capacity, fuel tanks of automobile are made from
polythene and nylon. This process is also used for production of large drums, boat hulls, buckets,
housings and carrying cases.
8 What is parison ?
Blow moulding consists of extrusion of the heated tubular plastic piece called as
parison which is transferred to the two piece mold.
9 Define degree of polymerization.
It is the number of repetitive units present in one molecule of a polymer.
Degree of polymerization = Molecular weight of a polymer
Molecular weight of a single monomer
10. 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.
11. Name the characteristic of polymer.(Any Four)
The important characteristic of polymers are
o Light weight
o High Corrosion resistance.
o Low density.
o Low thermal and electrical properties.
o Low mechanical properties (can be improved by fibre reinforcement of
plastics).
12. Give the mechanism of thermosetting polymers.
These plastics are formed by condensation polymerisation. During initial heating, covalent
cross-links are formed which anchor the chains together and resist the vibrational and rotational
chain motions at high temperature. If heated to excessively high
temperature, there occurs severance of these crosslink bonds leading to polymer degradation.

13. Differentiate thermosetting and thermoplastic polymers.

S.
Thermoplastics Thermosetting
No.

They are formed by

They are formed by addition
1 condensation.
polymerisation
 They are linear polymers composed of They are composed of three
2 chain molcules. dimensional network of cross- linked
molecules

14. Define Isomerism.

It is a phenomenon where different atomic configurations are responsible for the formation of
same configuration.
15. Define High polymers.
Polymers which have a very high molecular weight ranging between 10,000 and 1,000,000
g/mol. are known as High-polymers. They are mainly solids.
16. Give the three methods of mechanism of polymerisation :
There are three general methods or mechanisms of polymerisation :
Addition Polymerisation
Copolymerization
Condensation polymerisation
17. Define addition polymerization.
The Polymer is produced by adding a second monomer to the first, a third monomer to this dimmer
and so on till the long polymer chain is terminated. This process is called as addition
polymerisation.
18. Define condensation polymerisation and give its other name.
Condensation polymerisation is also known as step-growth polymerisation.
It is the formation of polymers by step wise intermolecular chemical reactions that normally
involve atleast two different monomers.

19. Why are additives used and enlist its advantages?

Additives used to improve the properties and performance of polymers. Advantages of additives
when added to the polymers are:
 Improve mechanical properties.
 Reduce the cost.
 Improve the thermal processing such as moldability.
 Improve the appearance and aesthetic properties.
 Improve surface and chemical characteistics of the polymers
20. Give the types of injection moulding.
Ram or Plunger type Injection Moulding
Screw type Injection Moulding
21. What are the applications of injection moulding?
Typical parts produced by this process are cups, chairs, toys, containers, knobs, automobile
parts ( car dash-board, car handles, etc), air conditioner parts, plumbing fittings, electrical fittings,
etc. This process is used for making components which consists of complex threads. Production of
intricate shapes and thin walled parts like radiator fan can be done by this process.
22. Enlist the types of blow moulding.
There are various types of blow moulding process which are as follows :
 Injection blow moulding
 Extrusion blow moulding
 Multi-larger blow moulding
[Link] is the difference between rolling and calendering?
The main difference between rolling and calendering is that, in calendering there is appreciable
thickening after the material has reached minimum thickness at the roll gap and the pre-calendered
material is not in the sheet form.
[Link] extrusion moulding .
Extrusion process is a continuous process in which the hot plasticized material forced through the
 die opening of required shape.
[Link] thermoforming.
It is a series of processes for forming thermoplastic sheet or film over a mould with the
application of heat and pressure.

26. 26. What are the processes used for thermosetting plastics?
For processing of thermosetting plastics following processes are most commonly used:
 Compression moulding and
 Transfer moulding
27. 27. Give the application of compression moulding.
Compression moulding is used for making flatware’s, gear, buttons, buckles,
knobs, handles, dishes, container taps and fittings Also used for moulding of electrical and
electronic components, washing machine agitators and housings.
[Link] is gate moulding?
This is the process of forming articles in a closed mould, where the fluid plastic material is
conveyed into the mould cavity under pressure from outside of the mould.
29. 29. Name the processing methods of plastics?
i) (i) Plug and ring forming (ii)pressure forming
(iii)Draw forming (iv)Reaction injection moulding (RIM) (v)Drape forming

[Link] pressure forming?

In this method, the heated plastics sheet is formed into the required shape between a pair of male
and female dies. In this process vacuum is not used.

PART B&C
1. Sketch and explain the injection molding process for plastics.
22. Discuss the advantage and application of compression and transfer molding process.
3. Describe thermoforming and transfer molding process.
4. Illustrate with suitable sketch the blow molding process for producing plastics serving
bottles.
[Link] the process of compression moulding with neat diagram.
6. Give the sequence of operation in transfer molding for thermosetting plastic process.
7. Describe the thermoforming process and thermosetting plastics.
8. Describe the various properties of plastics.
9. Why is screw injection molding machine better than a ram type injection molding machine.

COURSE INCHARGE HOD PRINCIPAL