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FRANCIS XAVIER ENGINEERING COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING
INTERNAL ASSESSMENT TEST-3/MODEL EXAM
ME 8351 – MANUFACTURING TECHNOLOGY-I
ANSWER KEY

PART_A (10 * 2 = 20 MARK)

1. Make a note on shrinkage allowance (CO1,K1)
As metal solidifies and cools, it shrinks and contracts in size
To compensate for this, a pattern is made larger than the finished casting by means of a
shrinkage or contraction allowance
Different metals have different shrinkages

2. What do you mean by core print? (CO1,K1)

Core print is an added or extra projection provided on pattern
It creates a seating in mold for core

3. Sketch an oxidizing flame in oxy acetylene gas welding. (CO2,K1)

Inner cone Outer envelope

4. What is the function of flux used in welding electrode? (CO2,K1)

To prevent atmospheric reaction
To improve weld strength
To add alloying elements
To create shield around the weld pool (if any two points written award two mark)

5. Define: Extrusion ratio. (CO3,K1)

It is the ratio of cross section of billet to cross section of extruded product

6. Differentiate hot working and cold working. (CO3,K4)

Mechanical working of metal above recrystallization temperature-hot working
Mechanical working of metal below recrystallization temperature-cold working
(For wring above differentiation provide 2 marks)
(Anyhow differentiation given in terms of example, force requirement, etc can also be
consider for the award of mark)

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7. Define Spring Back in bending operation. (CO4,K1)

Elastic recovery of sheet metal after releasing load

8. Distinguish redrawing and reverse drawing (CO4,K4)

Reverse redrawing of sheet metal, or reverse drawing, is sometimes used to redraw parts.
In reverse redrawing, the intermediate part is flipped over before being placed on the die
for the next operation. This will cause the sheet metal to now be drawn in the opposite
direction as the first draw. The amount of forming of the sheet metal that can be
accomplished on the first redraw is less than on the original draw. This redrawing process
can be done many times to achieve the final diameter and length of the desired deep
drawn cup.
9. What is ‘Parison’? (CO5,K1)
Parison is the hot extruded tube which is to be inflated into hollow geometry in blow
molding process.
10. Differentiate thermoplastic and thermosetting plastic (CO5,K4)
Thermoplastic -recyclability, become soft in heating, pressure not compulsory for
shaping example PVC,PE, electric plug
Thermosetting plastic-cannot be recycled, become hard in heating, need pressure and heat
for shaping, example-Phenol formaldyhyde, epoxy resin, electric wire insulation

PART_B (5 * 13 = 65 MARK)
11.(a) Explain hot chamber die casting process with a neat sketch (CO1,K2)
Diagram-5 Mark
Explanation-8 Mark
• In hot chamber die – casting, the melting furnace is an integral part of the mould.
• The operating pressure of hydraulic plunger is 15MN/m2
• Hot chamber die casting is suitable for casting of metals such as Zinc, tin and lead.

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The hot chamber machine contains the melting pot, while the cold chamber melt pot is separate
and the molten metal has to be ladled into the shot sleeve. With the internal mechanism, it makes
the hot chamber the faster of the two processes. Other advantages of the hot chamber process
include reduced porosity and longer die life from utilizing alloys that do not erode or dissolve the
machine when put under heat or high pressure. The injection mechanism of a hot chamber
machine is immersed in the molten metal. The furnace is attached to the machine by a metal feed
system called a gooseneck. 

The die is closed and the piston rises, opening the port, allowing molten metal to fill the cylinder
Next, the plunger seals the port, pushing the molten metal through the gooseneck and nozzle into
the die cavity where it is held under pressure until it solidifies.  The die opens and the cores, if
any, retract. The casting remains in only one die half – the ejector side. The plunger then returns,
allowing residual molten metal to flow back through the nozzle and gooseneck. Ejector pins push
the casting out of the ejector die. As the plunger uncovers the filling hole, molten metal flows
through the inlet to refill the gooseneck.

11.(b) Explain the principle of shell molding process with a neat sketch. Also, write its merits
and demerits (CO1,K2)
Scheme of Evaluation:
Diagram-5 Mark
Explanation-4 Mark
Merits and Demerits- 4 Mark

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The shell mold casting process consists of the following steps:

• The mold material contains 5 to 10% of phenolic resin mixes with fine dry silica. These
are mixed with either dry oil or in the presence of alcohol.
• The pattern is heated to about 230-600-degree C.
• After a specified time of 20-30 sec, the pattern and sand are inverted.
• In about 20-30 sec, we can get a normal shell thickness of 6mm.
• Then the mould is heated in an oven at 300-degree C for 15-60 sec.
Advantages
• A high accuracy casting with tolerances or ± 0.002 to 0.00mm/mm is possible.
• Good surface finish can be obtained
• Complex parts can be made by this method
• less sand is used compared to other methods

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• Molds can be stored for long time

• Permeability of thin shell moulds is high. Therefore, defects are less. Better quality
castings can be made.
Limitations
• Only small size of the castings can be made
• Serious dust and fume problem during sand and resin mixing will occur.
• Cost is more
• Carbon pickup may occur in the case of steels.
• While pouring the molten metal, the two halves are clamped down together by clams or
springs.
• After cooling and solidification, the shells are broken or shaken away from the castings.

12.(a)Explain with a neat sketch the working principles of Gas Metal Arc Welding(CO2 ,K2)
Scheme of Evaluation:
Diagram-5 Mark
Explaining the process -8 Mark

Gas metal-arc welding (GMAW) also called as metal inert-gas (MIG) welding, In Gas metal-
arc welding process the weld area is shielded by an effectively inert atmosphere of argon,
helium, carbon dioxide or various other gas mixtures. The consumable bare wire is fed
automatically through a nozzle into the welding arc by a wire-feed drive motor. In addition to
using inert shielding gases, de-oxidizers usually are present in the electrode metal itself in
order to prevent oxidation.
• The electric arc is produced between a consumable metal electrode and the work
piece.
• The current ranges from 100 to 400 A depending upon the diameter of the wire.
• The welding head may be either air or water cooled depending upon the current
being used.
• This process is used for welding thick plates. It is used for welding aluminium,
stainless steel, nickel, and magnesium without weld defects.
• The welding can be done manually or automatically

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12.(b) Sketch and explain working of the thermit welding process. (CO2, K2)
Scheme of Evaluation:
Diagram-5 Mark
Explanation-8 Mark

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Thermit welding is a chemical welding process in which an exothermic chemical reaction is used
to supply the essential heat energy. That reaction involves the burning of Thermit, which is a
mixture of fine aluminum powder and iron oxide in the ratio of about 1:3 by weight.

Although a temperature of 3000°C may be attained as a result of the reaction, preheating of the
Thermit mixture up to about 1300°C is essential in order to start the reaction.

The mixture reacts according to the chemical reaction:

8 Al + 3 Fe3O4 → 9 Fe + 4 Al2O3 + heat (3000˚C, 35 kJ/kg of mixture)

Thermit welding process is essentially a casting and foundry process, where the metal obtained
by the Thermit reaction is poured into the refractory cavity made around the joint.

The various steps involved in Thermit welding are:

1. The two pieces of metal to be joined are properly cleaned and the edge is prepared.

2. Then the wax is poured into the joint so that a wax pattern is formed where the weld is to be
obtained.

3. A moulding box is kept around the joint and refractory sand is packed carefully around the
wax pattern as shown in Fig. 7.40, providing the necessary pouring basin, sprue, and riser and
gating system. 4. A bottom opening is provided to run off the molten wax. The wax is melted
through this opening which is also used to preheat the joint. This makes it ready for welding.

5. The Thermit is mixed in a crucible which is made of refractory material that can withstand the
extreme high heat and pressure, produced during the chemical reaction.

6. The igniter (normally barium peroxide or magnesium) is placed on top of the mixture and is
lighted with a red hot metal rod or magnesium ribbon.

7. The reaction takes about 30 seconds and highly super-heated molten iron is allowed to flow
into the prepared mould cavity around the part to be welded.

8. The super-heated molten metal fuses the parent metal and solidifies into a strong
homogeneous weld.

9. The weld joint is allowed to cool slowly.

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13. ( a) Describe direct and indirect extrusions with neat sketches. (CO3, K2)
Scheme of Evaluation:
Diagram-6 Mark
Explanation-7 Mark
Extrusion
Extrusion is a Bulk Deformation Process in which the work is forced to flow through a die
opening to produce a desired cross-sectional shape.
Characteristics Of Hot Extrusion Process
• No fracture of metal due to tensile stress.
• Extrusion size depends upon the size of the cylinder.
• Hollow shapes also extruded.
• Forward or direct extrusion
• Backward or indirect extrusion.
Forward Or Direct Extrusion
• The heated billet metal is places in a press, which is operated by the ram and a cylinder.
• The heated metal billet is pushed by the ram and with the application of ram pressure the
metal first plastically fills the die
• Then it is forced out through the die opening and finally cut at the die face.

Indirect Or Backward Extrusion

• The extrusion part is forced through the hollow ram.
• The ram is operated by horizontal hydraulic drive.
The extruded metal is a pass through the hollow ram and it required less force compared to the
direct extrusion.

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13. (b) Describe open die, closed die, and fleshless forging. (CO3, K2)
Scheme of Evaluation:
Diagram-6 Mark
Explanation-7 Mark
Open Die Forging
• In this process, the forging is done in a heated work at the proper temperature by placing
on flat surface of anvil through hammering the metal piece.
• Hammering is done by giving repeated blows manually using hammer or by power
hammer. Heavy forgings weighing up to 25000 Kg are produced.
• This forging is very simple and flexible. It is very much useful for producing simple
shapes like U bolts, chisels, rectangular, circular, hexagonal shapes

•
Closed die forging:

Impression Die Forging pounds or presses metal between two dies (called tooling) that
contain a precut profile of the desired part. Parts from a few ounces to 60,000 lbs. can be made
using this process. Some of the smaller parts are actually forged cold. Commonly referred to as
closed-die forging, impression-die forging of steel, aluminum, titanium and other alloys can
produce an almost limitless variety of 3-D shapes that range in weight from mere ounces up to
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more than 25 tons. Impression-die forgings are routinely produced on hydraulic presses,
mechanical presses and hammers, with capacities up to 50,000 tons, 20,000 tons and 50,000 lbs.
respectively.
Applications:
• Spanner
• Automobile parts
Machine parts

14. (a) With neat sketches explain the Hydroforming. (CO4, K2)

Scheme of Evaluation:
Diagram-6 Mark
Explanation-7 Mark

• The required shape of inner configuration is made on the punch.

• A rubber diaphragm or seal is used for making perfect sealing between male and female
die.

In hydroforming or fluid forming process, the pressure over the rubber membrane is controlled
throughout the forming cycle, with maximum pressure reaching 100 MPa (15000 psi). This
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procedure allows close control of the part during forming to prevent wrinkling or tearing. When
selected properly, rubber forming and hydroforming processes have the following advantages:
Low tooling cost Flexibility and ease of operation
Low die wear
No damage to the surface of the sheet and Capability to form complex shapes.

14. (b) Explain the different types of bending process. (CO4, K2)
Scheme of Evaluation:
Diagram-6 Mark
Explanation-7 Mark
(Award 13 Mark for Any 6 Types Written and drawn)

Edge bending is another very

common sheet metal process and
is performed with a wiping die.
Edge bending gives a good
mechanical advantage when
forming a bend. However, angles
greater than 90 degrees will
require more complex equipment,
capable of some horizontal force
delivery. Also, wiping die
employed in edge bending must
have a pressure pad. The action of the pressure pad may be controlled separately than that
of the punch.
Beading:
It is a process in which the periphery of the sheet metal is bent into the cavity of a die. It
increases moment of inertial of the section and stiffness. It also eliminates exposed sharp edges.

Flanging:
It is a process of bending the edges of the metal sheet at perpendicular to the length. It can be
further divided according the shape like straight flange, stretch flange, joggled flange, shrink
flange etc. as shown in figure.

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Hemming:
It is an operation in which the edge of the sheet is folded over itself. This process increases
stiffness of the part and eliminate sharp edges.

15. (a) Explain the injection molding process of screw type with neat sketches. (CO5, K2)

Diagram-6 Mark (modified sketches according to concept also be considered for the award
of mark)
Explanation-7 Mark

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Equipment for injection molding evolved from metal die casting. An injection molding machine
consists of two principal components: (1) the plastic injection unit and (2) the mold clamping
unit. The injection unit is much like an extruder. It consists of a barrel that is fed from one end by
a hopper containing a supply of plastic pellets. Inside the barrel is a screw whose operation
surpasses that of an extruder screw in the following respect: in addition to turning for mixing and
heating the polymer, it also acts as a ram which rapidly moves forward to inject molten plastic
into the mold. A non-return valve mounted near the tip of the screw prevents the melt from
flowing backward along the screw threads. Later in the molding cycle the ram retracts to its
former position. Because of its dual action, it is called a reciprocating screw, which name also
identifies the machine type. Older injection molding machines used a simple ram (without screw
flights), but the superiority of the reciprocating screw design has led to its widespread adoption
in today's molding plants. To summarize, the functions of the injection unit are to melt and
homogenize the polymer, and then inject it into the mold cavity
The clamping unit is concerned with the operation of the mold. Its functions are to (1) hold the
two halves of the mold in proper alignment with each other; (2) keep the mold closed during
injection by applying a clamping force sufficient to resist the injection force; and (3) open and
close the mold at the appropriate times in the molding cycle. The clamping unit consists of two
platens, a fixed platen and a movable platen, and a mechanism for translating the latter. The
mechanism is basically a power press that is operated by hydraulic piston or mechanical toggle
devices of various types. Clamping forces of several thousand tons are available on large
machines.
15. (b) Discuss in detail about blow molding process with neat sketches. (CO5, K2)

Diagram-6 Mark
Explanation-7 Mark
Award mark if injection blow mold is explained and drawn
Extrusion Blow Molding
This form of blow molding consists of the cycle illustrated below. In most cases, the
process is organized as a very high production operation for making plastic bottles. The
sequence is automated and usually integrated with downstream operations such as bottle
filling and labeling. It is usually a requirement that the blown container be rigid, and
rigidity depends on wall thickness among other factors.
Steps followed in extrusion blow molding are (1) extrusion of parison; (2) parison is
pinches at the top and sealed at the bottom around a metal blow pin as the two halves
of the mold come together; (3) the tube is inflated so that it takes the shape of the mold
cavity; and (4) mold is opened to remove the solidified part.

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PART_C (1 * 15 =15 MARK)

16.(a) Discuss various types of casting defects, their causes and the ways of eliminating them
with neat sketches. (CO1 , K2)
Any 8 defects ( 7*2= 14)+(1*1=1) with causes and remedy and drawing award 15 mark

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16. (b) Why the solid state welding processes are preferred over fusion welding process during
the joining of dissimilar metals? Explain anyone of solid state welding process and highlight
their specific advantages. (CO2 , K2)
In all those welding processes where melting of faying surfaces of parent materials don’t
take place are called solid-state welding. Unlike fusion welding, here application of heat is not
necessary. However, application of pressure is required for getting a sound joint and thus it is
also termed as Pressure welding. It is worth nothing that sometime base materials are heated to
an elevated temperature while joining by sold-state welding process; however, temperature
always remains below melting point. (2 MARK)
Advantages of solid-state welding processes
Because of no melting and solidification, these processes provide comparatively lower lever of
distortion and residual stress generation.
Heat affected zone (HAZ) is also narrower.
It provides sumptuous weld appearance.
Mechanical properties of parent materials remain intact as no fusion takes place.
Easy to join dissimilar metals. (3 MARK)
Examples of solid-state welding
Cold Welding (CW)
Roll Welding (ROW)
Pressure Welding (PW)
Diffusion Welding (DFW)
Forge Welding (FOW)
Friction Welding (FRW)
Friction Stir Welding (FSW)
Explosion Welding (EXW)
Ultrasonic Welding (USW)
(NOTE : IF any one of the above is explained with necessary details provide 10 mark)
Friction welding (FRW) is a solid-state welding process that generates heat through mechanical
friction between workpieces in relative motion to one another, with the addition of a lateral force
called "upset" to plastically displace and fuse the materials. Because no melting occurs, friction
welding is not a fusion welding process in the traditional sense, but more of a forge welding
technique. Friction welding is used with metals and thermoplastics in a wide variety of aviation
and automotive applications.
The combination of fast joining times (on the order of a few seconds), and direct heat input at the
weld interface, yields relatively small heat-affected zones. Friction welding techniques are
generally melt-free, which mitigates grain growth in engineered materials, such as high-strength
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heat-treated steels. Another advantage is that the motion tends to "clean" the surface between the
materials being welded, which means they can be joined with less preparation. During the
welding process, depending on the method being used, small pieces of the plastic or metal will
be forced out of the working mass (flash). It is believed that the flash carries away debris and dirt
Another advantage of friction welding is that it allows dissimilar materials to be joined. This is
particularly useful in aerospace, where it is used to join lightweight aluminum stock to high-
strength steels. Normally the wide difference in melting points of the two materials would make
it impossible to weld using traditional techniques, and would require some sort of mechanical
connection. Friction welding provides a "full strength" bond with no additional weight. Other
common uses for these sorts of bi-metal joins is in the nuclear industry, where copper-steel joints
are common in the reactor cooling systems; and in the transport of cryogenic fluids, where
friction welding has been used to join aluminum alloys to stainless steels and high-nickel-alloy
materials for cryogenic-fluid piping and containment vessels. (6 MARK)

(4 MARK)

Prepared by verified by HOD

(G.VAIRAMANI)

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