QP Code: 352 October 2019 ANSWER KEY Manufacturing Processes Year/Sem: II / Ill ‘Subject Code: 32032 PART-A Define solid piece pattern. This type of pattern is made of single piece. There are no loose piece and joints, Solid pattern is suitable for manufacturing of medium and small size castings. (Definition 2 Marks) Name the pressure die casting methods. - Hot chamber die casting method = Cold chamber die casting method (Two methods ~ 1 Mark +1 Mark) F Define welding. Welding is defined as “a fusion welding process that uses electricity to generate the heat needed to melt the base metal.” The joint is formed after the solidification of molten metal (Definition 2 Marks) What is flame cutting? Flame cutting is a process that uses fuel gases and oxygen to cut the metals. It is also called as ‘oxy fuel cutting’. This process is also used for metal plate edge preparation, (Definition or Concept description 2 Marks) Define forging. Forging is the process to get the required shape in the metal by the application of a compressive force. (Definition 2 Marks) Name the two types of head stocks of centre lathe. - Step-cone pulley head stock - All geared head stock (Two types - 1 Mark + 1 Mark) Define drilling. Drilling is @ cutting process that uses a drill bit to cut a hole of circular in cross- section on the solid materials. (Definition 2 Marks) What is infiltration? The molten metal with low melting point is forced into the porous of the sintered product under pressure. Thus the molten metal enters the pores, occupies and increases density, hardness and strength of the sintered products. (Concept description 2 Marks) Page 1 of 1210. " 12. PART-B Explain any one pattern allowance. ~ Shrinkage allowance - Draft or taper allowance = Machining or finishing allowance ~ Distortion allowance = Rapping or shaking allowance (Definition 2 Marks + Sketch 1 Mark) uu Draft or taper allowance Distortion or camber allowance State any three essential qualities of a core. - Good refractoriness - High collapsibility for avoiding hot tears: and cracks = High permeability = Smooth surface finish (Any three essential qualities ~ 3x 1=3 Marks) Sketch and explain spot welding. Inthe spot welding, the metal pieces are assembled and placed between two copper electrodes and then electric current is passed, The metal pieces are heated on the cect areas due to electrical resistance. Then the electrodes ere ‘operated to press corraetal pieces, Spot welding is used to make lap joints, The sheet metal thickness generally varies from 0.025mm to 1.2mm, (Sketch 1 Mark + Explanation 2 Marks) Spot welding Sketch and explain radiographic test. pele test piece is placed in front of X~ay tube and X-ray fm is placed at the bottom toe feat piece. Now the X-ray ftom X-ray tube is passed through the test piece and Srae'tne image is recorded on the fim. any defects in the test piece, it will be shown inthe fim as bright spot. If there no defects the image will be uniform, X-ray test is ie tind out mainly porosity and biow holes in the welded joints Sketch 1 Mark + Explanation 2 Marks) Page 2 of 12 yray / Radiographic Test13. 14, 15. Sketch and explain angle bending. This operation Is carried out for bending the sheet metal into the acute angle. Punch and die are used for bending the sheet metal. The punch and die have cavity and projection for bending the sheet metal. (Sketch 4 Mark + Explanation 2 Marks) Angle bending State any three functions of cutting fluid. - To coo! the tool and prevent heat generated at tool face and to increase the life of tool and good surface finish. = To cool the workpiece and thus prevent the excessive thermal distortion of workpiece material. = To improve the surface finish (Any three functions - 3 x 1 Mark = 3 Marks) Explain deep hole drilling. Deep hole driling is the operation used for, making @ small and lengthy hole on the workpiece. Deep hole driling is done on the parts such as crank shaft, cam shaft, rifle barrels and long shafts. The deep hole drill has one vee flute of 100° included angle. The flutes are parallel to the entire length of drill. Coolant is forced to the ‘cutting edge through a long hole provided in the drill body. (Sketch 1 Mark + Explanation 2 Marks) Coolant out way Ol hole Deep-hole drilling Page 3 of 1216. 17.8) Write about Geneva indexing mechanism. Pee aechanism which is used to convert rotary motion into intermittent rotaty ts 2 is used to feed the turret lathe and machine tool indexing table. It consists Of driving wheel (X) which acts as a crank. It carries a pin which engages 1° slot of of arvind Whee! (Y) called as geneva wheel. Generally, the geneva wheel has # fo re ete as per the requirement of indexing. When the crank rotates one revolution the geneva wheel rotates a fractional pat ofa revolution. For example, when geno vr oe has four slots, geneva wheel will rotate one quarter of revolution or ninty degree for one revolution of the crank. (Gketch 1 Mark + Explanation 2 Marks) Daven hae or Geneva whees(¥) ~ Driving whoa mck x) Geneva Indexing Sketch and explain the jolting machine and the sand slinger. Jolting Machine: ‘The pattem is placed in the moulding box on the table. Moulding box is filled up with moulding sand. The table with moulding box is raised to about 60mm and then suddenly dropped. The table will be raised by plunger when ‘compressed air enters tinder plunger through channel. Then the table will be dropped suddenly when the air escapes through the hose. Due to the sudden fall of table, the sand in the moulding box is packed evenly around the pattern. Spring is used to absor> the vibrations and foreduice the noise of the table. Ramming is done individually in the cope and drag box. (Sketch 2 Marks + Explanation 3 Marks) Jolting Machine Page 4 of 1217.(b) Sand Slinger: Sand slinger is used to throw the moulding sand into the moulding box by n impeller. The impeller head is in the housing. The blades rotate with an high speed inside the housing. The sand is delivered to the impeller through the opening by conveyor buckets. The sand is thrown by impeller head over the pattern through the outlet with a high velocity. Moulding sand density can be controlled by the speed of the table. This method is suitable for large moulds. Uniform ramming can be obtained and can be done quickly. But the cost of machine is high. The moulding has more strength in this method. (Sketch 2 Marks + Explanation 3 Marks) Sand Slinger Sketch and explain the blast furnace. Blast furnace: The blast furnace is an equipment which is used to produce iron from iron ores. The most commonly used iron ores are haematite and magnetite. The blast furnace is used to reduce chemically and convert physically the iron ores into liquid (molten) iron. The blast furnace is a large steel stack lined with refractory brick. The iron ore, coke and limestone are dumped into the top. The preheated air is blown into the bottom. Due to this, the mixture of iron ore, coke and limestone becomes the final product of liquid (molten) iron and liquid slag. The liquid iron is tapped at the bottom of the blast furnace. Similarly, the liquid slag is also tapped from slag tap hole. The liquid products are drained from the furnace at regular intervals, (Sketch 5 Marks + Explanation 5 Marks) Blast Furnace Page 5 of 1218.(a) 18.(b) ‘Sketch and explain submerged arc welding and state its applications. ‘Submerged Arc Welding: Ite alge called hidden arc welding. Electric arc is produced between consumable lectrode and the workpieces. But, the arc is completely hidden under the flux powder, The arc is not visible. Electrode is fed continuously from the hopper and it's coin front of the moving head. There wil not be any defect because the arc is completely converted by flux powder. ‘Applications: Its suitable for cylinders, steel pipes etc. it can be used to weld carbon Steels and alloy steels and chromium steels. Plates of 12mm to 50mm thickness can be welded with one pass. (Sketch § Marks + Explanation 3 Marks + Application 2 Marks) Submerged Arc Welding ‘Sketch and explain the gas welding equipment set up. The following equipment are used for gas welding: Gas cylinders ‘Oxygen and acetylene gases are used in gas welding. These gases are stored in separate cylinders. The colour of oxygen cylinder is black. Itis stored in cylinder at a pressure of 125 to 140 kg/em®. The colour acelylene cylinder is maroon. Itis stored at a pressure of 16kg/cm?. Fusible plug is fitted with acetylene cylinder to avoid explosion. Pressure regulator Each cylinder is fitted with a pressure regulator. Regulator is used to reduce and control the working pressure of the gas. Working pressure of the oxygen is between 0.7 and 2.8kg/cm? and for acetylene pressure is between 0.07kg/cm? and 1.03kg/ ane Pressure gauges Two pressure gauges are fitted in each cylinder. One pressure gauge is used to show the cylinder pressure another one for showing working pressure of welding Hoses Hoses is used to connect each cylinders regulators and torch. Oxygen cylinder is connected with black colour hose and acetylene cylinder is connected with red colour. Page 6 of 12Welding torch ‘Oxygen and acetylene gases enter into the torch from this cylinder through the hoses in separate passages both gases are mixed in mixing chamber of the torch. When the gases are ignited, flames is produced at th tip ofthe torch, Nozzles are made of ‘copper or copper alloy. Goggles : ‘These are used to protect eyes from the ultra violet and infrared rays. Welding gloves Gioves ar used fo protect hand fromthe ur caused by metals eplashes, (Sketch § Marks + (Ex purpose on each 1x1 Mark=5 Marks)) Gas welding equipments set-up 19.(a) Sketch and explain the drop Torging and press forging operations. Drop forging: op Closed impression dies are used in drop forging. The hot metal is pressed between the cavities of the set of dies. Dies are made to the required shape. Upper die is fitted on the Ram and the Lower die fitted on the anvil. Two rollers are fixed on the board when both rollers rotate opposite to each other, it drives the board upward and lifts the ram. When the rollers are released the ram will fall down and press the work piece. Drop forging is used for making spanner, automobile parts and machine parts. ‘Advantages ~ Suitable for mass production, Less wastage. (Sketch 2 Marks + Explanation 3 Marks) Drop Forging19.(b) Press forging: x itis done by using press. The hot metal is squeezed in the die cavily. The press is ‘operated by hydraulically or mechanically. Forging completed in a single stroke dio is reed in the press, Die Is divided into two parts such as upper haif and lower half. And those halves having the impressions of the shape to be produced. Lower half is fixed te the anvil and the upper half is fitted to the ram. The ram is operated to move down and presses the metal with high pressure. So, the hot metal flows into the die cavity Then the finished part is removed automatically by electors. ‘Advantage — Parts can be manufactured by single stroke. (Sketch 2 Marks + Explanation 3 Marks) Press Forging Sketch and explain any two press working operations. Bending operations — Angle bending, Curling, Channel bending, Drawing, Shearing operations — Blanking, Piercing, Trimming, Notching, Lancing, Parti Bending operation: ‘Angle bending - This operation is carried out for bending the sheet metal to the acute angle. Punch and die are used for bending the sheet metal. The punch and ide have cavity and project for bending the sheet metal. - Curling - Its the operation of bending edge in the form of curl, Dies are used in the press for curling operation. The dies have the required shape of curling. The lower fie is fixed type, The upper die moves down slowly and made the curl on the edge of the workpiece. Curling is done on the edges of pots, cups, cans etc. Channel bending - The sheet metals is fed between two rollers to produce the required shape of channel. The sheet metal is passed upto three or four stages. The number of stages depends on the thickness of the metal and the type of metal. Drawing - The press used for drawing operation has open die, punch and pressure pad. In this operation, the sheet metal is pressured to require cup shape. The metal piece is placed on the die and held by a pressure pad. Then the punch is forced with Figh pressure on the metal piece. Due to this, the metal piece flows into the cavity of the dle and forms to the required cup shape. The ejector is used for remove the cup 5m the die. Page 8 of 12Shearing operations: Blanking — is the operation of cutting out flat pieces with required shape. This first piece is blank. A metal strip is removed during the blanking operation. Piercing — is an operation of producing hole in a plate. Trimming — unwanted portion of press worked parts removal. Nothing — the different shapes of notches.on the edges on the metal are produced. Lancing — is an operation of producing an incomplete cut and bending that pfortion. Parting-off — is carried out through which the metal is cut simultaneously along two parallel ines or contours or any other two lines which can be balanced on each other to neutralize side thrust. (For each operation - Sketch 2 Marks + Explanation 3 Marks) (Any two operations - 2 x § Marks = 10 Marks) Drawing Curling Channel Bending Piercing Page 9 of 12Trimming, Blanking 20.(a) Sketch and explain the orthogonal and oblique metal cutting principles. Orthogonal Notchine Lancing Partine-off 1 cutting (Two dimensional): When the cutting face of tool is 90degree to the path of tool, then it is called ‘orthogonal cutting, In orthogonal cutting, the cutting edge of the tool is at right angles fo the direction of the relative velocity of work. The force which cuts the metal and ‘acts on smaller area. The chip formation in orthogonal is a flat spiral form. Itis also called as two dimensional cutting. (Sketch 2 Marks + Explanation 3 Marks) Orthogonal cutting Oblique cutting (Three dimensional): ‘The cutting face of the tool is inclined at an angle less than 90degree to the path of the tool. The force which cuts the metal acts on a longer area. This type of cutting has low heat generation and the life of tool is long. On comparing with orthogonal cutting, this type of cutting is removing more metal even though the depth of cut and feed is same. The chip formation is oblique cutting is a long curl. (Sketch 2 Mat Janation 3 Marks) Page 10 of 12 Oblique cutting20.(b) 21.(a) Sketch and explain the three jaw and four jaw chucks. Three jaw and self-centring chuck: This type of chuck has three jaws, All the three jaws can be moved in equal distance in radial direction using chuck key. Three jaw chuck has nine circular disc. Spiral scroll is made on front of the disc and bevel teeth of disc. When the chuck key is tumed, the bevel pinion and disc will rotate. So the jaws in the scroll will move in radial distance. This type of chuck is used to hold the regular shaped work piece like round and hexagonal. (Sketch 2 Marks + Explanation 3 Marks) Three jaw/self-centring chuck Four jaw or independent chuck: Four jaw chuck is used for holding regular and irregular shape work pieces. It has four jaws each jaw can be moved individually because these jaws have slots has the back side to mesh with screws. Each jaw is fitted with screw. The screws have ‘square hole at the top to receive chuck key. So, we can rotate the screw by chuck key when the chuck key is turned in the slot, that particular jaw only move. So, the irregular shape work piece and large work piece can be held in this chuck. (Sketch 2 Marks + Explanation 3 Marks) Four jaw chuck Explain the countersinking and counter boring operations with sketches. Counter sinking: This operation of making a cone shaped enlargement on the end of the hole is called countersinking, Flat head screw or counter sink rivets are seated in the countersinked part. The included angle of a countersink tool is 60, 82 to 90 degree. (Sketch 2 Marks + Explanation 3 Marks) Counter boring: ‘Counter boring operation is nothing but the operation of enlarging the end of a hole cylindrically for seating the heads of parts such as bolts, nuts, studs and pins. The cutting edge of the tool may be straight or spiral. (Sketch 2 Marks + Explanation 3 Marks) Page 11 of 12Counter boring 21.(b) Sketch and explain the feeler gauge and vernier height gauge. Feeler gauge: ‘These gauges are used for measuring the clearance between the two mating parts. It consists of strips of sheet of different thickness. These strips are assembled together ina holder. Mostly these gauges are used in automobile field. (Sketch 2 Marks + Explanation 3 Marks) Vernier height gauge: Itis a precision instrument used to measure and mark vertical heights. It is used to measure the difference in heights. Vertical column is also called as bearn or bar. The projection of the jaw should be at least 25mm. The auxiliary head is attached to the beam above sliding vernior head. It has line adusting and clamping screw, The method of measurement is very similar to the vernier calliper. The measuring faces (of the beam, measuring jaw and this scriber)should be tested for straightness, squareness and parallelism. (Sketch 2 Marks.+ Explanation 3 Marks) Feeler gauge Signature: (Arcee Name: K Sreenivasan ceo, Designation: Lecturer Production Engg. MEGROOE. foc pontese2, |__ ‘enone _ + CeO EY Peper Us Corcect end here Broo | to beaopitiation Lond abferktion jo érswoe BCS age 2 Me 25 Arnplemented. )» (222 Goa2L £6 aT) alegapion— bs Pregl ) BNA evimaontics) & SfaserAstodl Batzaco!). 9» y 33 SAQ003