Chapter 1 & 2 Metal casting process

Transcription

1 Chapter 1 & 2 Metal casting process GTU Paper Analysis Sr. No. Questions June 15 Jan 15 June 16 Nov 16 June 1 Nov 1 Theory 1. Explain the importance of Manufacturing Processes in context of recent development. 2. Give broad classification of various manufacturing processes. Also describe the factors affecting the selection of manufacturing process for a product Draw the schematic sketch of Gating system for casting. Mention the working function of each Gating system elements. 4. What is pattern? Explain the following patterns with a schematic diagram. (1) Gated Pattern (2) Follow board Pattern (3) Split Pattern 5. Explain the Dump box shell moulding process with sketch. 6. What is the difference between sand and shell mold casting?. State the types of furnaces used in foundries discuss in brief the working of cupola furnace. 8. What is permanent mould casting? Describe Die casting with figure. 9. What is taper or draft? Explain it briefly State the Chvorinov s rule. Discuss it briefly Explain when casting is preferred over forming Explain the functions of Facing sand,backing sand,system sand, andcore sand Explain what a pattern is. Explain the advantages and limitations of plasters over plastics as pattern materials. State the properties of moulding sand and explain the importance of any four properties for the production of sound castings. 4 4

2 15. Compare capabilities of sand casting and investment casting in context of weight (size), as cast dimensional accuracy, economic quantity. Hence bring out the applications of both processes. GTU Paper Analysis 16. Explain how and why chills improve the effective feeding distance in castings What is gating ratio? What is pressurized and non-pressurized gating system? What type 4 of gating ratio should be chosen for Aluminum alloys? For steels? Why? 18. Explain principle of centrifugal casting process, its capabilities and applications. How the impurities are taken care of? 19. Explain Blow holes, Misrun & Warpage in terms of castings Explain Precision Investment Casting with Figure. Example 1. During sand mould casting process, it took 155 sec for a cube-shaped casting to be solidify. The cube is 50 mm of side. 1) Determine the value Cm of the mold constant in Chvorinov's Rule. 2) If the same alloy and mold type were used, find the total solidification time for a cylindrical casting in which the radius r = 15 mm and length h = 50 mm.

3 Chapter 3 Metal Joining Process Sr. No. Questions Jun 15 Jan 16 June 16 Nov 16 June 1 Nov 1 Theory 1. Describe the types of flame obtained in oxy-acetylene gas welding with neat sketch Write short note on Electron beam welding. 3. What is laser beam welding process? Explain the steps involved in the process and state its application. 4. Explain the various metal joining process along with the types of welding process. 5. Explain the working principles of Oxy-acetylene gas welding and gas cutting processes. Also differentiate between nozzles used for Oxy-acetylene gas welding and gas cutting process, using sketch. 6. Explain the common welding defects by stating their causes and their remedies.. Describe explosive welding process with its advantages and limitations Explain the working principle of Resistance welding. Differentiate between Spot and Seam Welding processes. 9. Sketch and label four positions of welding Describe the Atomic Hydrogen Welding with neat sketch. 11. How is polarity defined in DC welding source? Draw the sketch of a carburizing oxyacetylene flame What is arc blow? Explain the principle of Arc welding State the parameters affecting the arc in arc welding With a neat sketch, explain TIG arc welding. 3

4 1. Discuss the function of flux during welding. State the ingredients of flux Explain the basic procedure in SAW with a neat sketch. What is back up in SAW? 19. Why oxy-acetylene gas cutting is not preferred for cutting non-ferrous metals? Define a welding arc What is the method of arc initiation in MIG welding? Explain why a flux or a gas shielding is not used in resistance spot welding What is the choice of current and polarity that results with higher penetration in shielded 3 metal arc welding? Why? 24. Explain how a weld (coalescence) is formed in friction welding. Hence state advantages, 4 disadvantages and applications of friction welding. 25. What is the choice of welding speed for an overhead position compared to down hand 3 position welding? Why? 26. What is difference between brazing and soldering? Hence state their applications Why do we use welding symbols? Explain Basic symbol with figure Describe types of welding joints and explain any two in brief. 4

5 Chapter 4 - Metal Forming Process Sr. No. Questions Jun 15 Jan 16 June 16 Nov 16 June 1 Nov 1 Theory 1. Explain the principle and operation of Rolling process. 2. Differentiate between forward extrusion and backward extrusion Describe the piercing and blanking processes. Also explain the terms: Ingot, slab, bloom and billet. State the hot working and cold working process advantage and disadvantages of the process. 5. Classification of rolling process according to the shape of rolling. 6. Explain wire drawing and tube drawing with neat sketches.. Enlist the various types of presses used in forging explain with neat sketch. 8. Importance of recrystallization temperature for mechanical working processes Differentiate between Hot and Cold working processes Explain the effect of Strain Hardening With neat sketch explain punching and bending Explain the cutting operation for press working State the advantages and limitations of forging process. 14. Discuss the defects, causes and remedies of forging defects. 15. A U-bend shows wrinkles in the flat portion present between bends. What can be the probable cause? Suggest suitable remedy with due justification. 3

6 Compare main features, limitations and applications of open die forging and closed die forging. 1. What types of product forms that are produced by rolling? Sketch each of them Explain the characteristic features of a deep drawing operation in context of the state of stresses in the different parts of a drawn cup, process variables and their effect and probable failures. Explain elastic and plastic deformation process in detail with neat sketch in metal shaping/forming processes.

7 Chapter 5 - Plastic, Ceramic and Glass Processing Sr. No. Questions Jun 15 Jan 16 June 16 Nov 16 June 1 Nov 1 Theory 1. Classification of plastic and its general properties Explain with neat sketch injection moulding process. What are the limitations of this process? 3. Draw the various glass structure explain properties and application of glass manufacturing. 4. Explain blow moulding process stating its advantages, limitation and application. 5. Explain Injection moulding process for plastic, by stating its principle of operation, advantages, limitation and applications. 6. Distinguish between thermoforming process and extrusion process for plastics.. Completely describe the metal matrix composite processing methods (any two) Enlist the Plastic manufacturing processes State the advantages and disadvantages of Compression molding process Explain, with a neat sketch, transfer moulding process With a neat sketch, explain injection moulding and blow moulding. 12. Explain calendaring process Explain glass forming process What is a ceramic? List the commonly used ceramic matrix composites processing techniques. State the applications of ceramic matrix composites.

8 15. What are the processing steps in making the ceramic parts? With the help of a general block diagram, explain how a ceramic part is made from raw material. How and why the processing is different than that of processing of metals and alloys? GTU Paper Analysis 16. Enlist various ceramic structures and explain any one in detail 4 1. Explain Polyethylene, Polypropylene and Polyvinyl Chloride in brie 3