QUESTION PAPER CODE: 21557

B.E/B.Tech. DEGREE EXAMINATION, MAY/JUNE 2013

THIRD SEMESTER

Mechanical Engineering

ME 2201/ME 32/10122 ME 302/PR 1204/080120005- MANUFACTURING TECHNOLOGY-I

(Common to Industrial Engineering and Industrial Engineering and management)

(Regulation 2008/2010)

Time: Three hours Maximum: 100 marks

Answer All Questions

PART A- (10X2=20 marks)

1. Compare the advantage of metal moulds over sand (expandable) moulds.

Expendable Mold Permanent Mold

 Can produce one metal casting only
 Made of sand, plaster, or other
similar material
 Binders used to help material hold
its form
 Mold that metal solidifies in must be
destroyed to remove casting
 More intricate geometries are
possible for casting
 Can manufacture many metal castings
 Usually made of metal or sometimes a
refractory ceramic
 Mold has sections that can open or close,
permitting removal of the casting
 Need to open mold limits part shapes

2. What are the functions of flux in melting metals and alloys

Fluxes are specifically used to remove gas or prevent its absorption into the melt, to reduce metal
loss, to remove specific impurities and nonmetallic inclusions, to refine metallic constituents, or to
lubricate and control surface structure in the semicontinuous casting of mill alloys.
3. What is the minimum distance maintained between two successive spot welds made by resistance
welding? Why?
4. Write short notes on transferred and non transferred arc in plasma arc welding.
Special form of GTAW in which a constricted plasma arc is directed at weld area. Tungsten
electrode is contained in a nozzle that focuses a high velocity stream of inert gas (argon) into arc region
to form a high velocity, intensely hot plasma arc stream. Temperatures in PAW reach 28,000 C (50,000
F), due to constriction of arc, producing a plasma jet of small diameter and very high energy density
5. What is ironing?
Ironing of sheet metal is a manufacturing process that is mostly used to achieve a uniform wall
thickness in deep drawings. Variation in wall thickness often exists in parts produced by deep drawing,
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 as discussed in the previous section. Ironing of sheet metal can be incorporated into a deep drawing
process or can be performed separately. A punch and die pushes the part through a clearance that will
act to reduce the entire wall thickness to a certain value. While reducing the entire wall thickness,
ironing will cause the part to lengthen. The percentage reduction in thickness for an ironing operation is
usually 40% to 60%. Percent reduction can be measured
6. What is meant by fullering?
7. Define spring back.
Springback, also known as elastic recovery, is the result of metal tending to return to its original
shape after undergoing compression and tension (stretching). All metals have what is called an elastic
limit.
8. Why it is necessary to provide proper clearance between the punch and die in a shearing operation?
In blanking operation , the die size is taken as the blank size and the punch is made smaller
giving the necessary clearance between the die and the punch.
Die size        = blank size
Punch size  = blank size – 2 x clearance
Clearance   = k . t . t
where t is the shear strength of material, t is the thickness of sheet metal stock, and k is a
constant whose value may be taken as 0.003.
In a piercing operation , the following equations hold.
Punch size = blank size
Die size      = blank size + 2 x clearance
Clearance = k . t . t
9. What is polymerization?
In polymer chemistry, polymerization is a process of reacting monomer molecules together in a
chemical reaction to form polymer chains or three-dimensional networks.
10. What is calendaring in processing of plastics?
Calendering is a speciality process for high-volume, high quality plastic film and sheet, mainly
used for PVC as well as for certain other modified thermoplastics. The melted polymer is subject to heat
and pressure in an extruder and formed into sheet or film by calendering rolls.

PART B- (5X16=80 MARKS)

11. (a) (i) What are the allowances given while making pattern? Explain. (8)
Pattern Allowances
Five types of allowances were taken into consideration for various reasons. They are
described as follows:
1. Shrinkage allowance
2. Draft allowance
3. Finish allowance
4. Shake allowance
5. Distortion allowance

(ii) Describe the process of Investment casting. What process controls are need in this case?(8)

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 Investment Casting
Investment casting produces very high surface quality and dimensional accuracy.
Investment casting is commonly used for precision equipment such as surgical equipment, for
complex geometries and for precious metals. This process is commonly used by artisans to
produce highly detailed artwork. The first step is to produce a pattern or replica of the finished
mould. Wax is most commonly used to form the pattern, although plastic is also used. Patterns
are typically mass-produced by injecting liquid or semi-liquid wax into a permanent die.
Prototypes, small production runs and specialty projects can also be undertaken by carving wax
models. Cores are typically unnecessary but can be used for complex internal structures. Rapid
prototyping techniques have been developed to produce expendable patterns. Several replicas are
often attached to a gating system constructed of the same material to form a tree assembly. In
this way multiple castings can be produced in a single pouring.

Casting with expendable mould: Investment Casting

Advantages
– Parts of great complexity and intricacy can be cast
– Close dimensional control and good surface finish
– Wax can usually be recovered for reuse
– Additional machining is not normally required - this is a net shape process
Disadvantages
– Many processing steps are required
– Relatively expensive process
OR
(b) (i) Briefly explain the principle, operation, advantages, disadvantages and application of Co 2
moulding (8)
Carbon Dioxide Moulding
• This sand is mixed with 3 to 5 % sodium silicate liquid base binder in muller for 3 to 4
minutes. Additives such as coal powder, wood flour sea coal, dextrine may be added to improve
its properties.
• Aluminium oxide Kaolin clay may also added to the sand.
• Patterns used in this method may be coated with Zinc of 0.05 mm to 0.13 mm and then
spraying a layer of aluminium or brass of about 0.25 mm thickness for good surface finish and
good results.
Advantages
• Operation is speedy since we can use the mould and cores immediately after processing.
• Heavy and rush orders
• Floor space requirement is less
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 • Semi skilled labour may be used.
Disadvantages
Difficult in reusing the moulding sand.
(ii) Describe with a neat sketch of cold chamber die casting machine. Give its Advantage and
limitations (8)
Cold Chamber Die Casting
In a cold chamber process, the molten metal is poured into the cold chamber in each
cycle. The operating cycle is
(i) Die is closed and molten metal is ladled into the cold chamber cylinder;
(ii) Plunger pushes molten metal into die cavity; the metal is held under high pressure
until it solidifies;
(iii) Die opens and plunger follows to push the solidified slug from the cylinder, if there
are cores, they are retracted away;
(iv) Ejector pins push casting off ejector die and plunger returns to original position.
This process is particularly useful for high melting point metals such as Aluminum, and Copper
(and its alloys).

Advantages
– Economical for large production quantities
– Good dimensional accuracy and surface finish
– Thin sections are possible
– Rapid cooling provides small grain size and good strength to casting
Disadvantages
– Generally limited to metals with low metal points
– Part geometry must allow removal from die cavity
12. (a) (i) Explain any four major ways to control the output of arc welding transformer (8)
The transformer type produces only alternating current.  They are commonly called
"Welding Transformers."  All AC types utilize single-phase primary power and are of the
constant current type. The rectifier types are commonly called "Welding Rectifiers" and produce
DC or, AC and DC welding current.  They may utilize either single phase or three phase input
power.  They contain a transformer, but rectify the AC or DC by the use of selenium rectifiers,
silicon diodes or silicon controlled rectifiers.  Available in the constant current or the constant
voltage type, some manufacturers offer units that are a combination of both and can be used for
coated electrode welding, non-consumable electrode welding and for welding with solid or flux
cored wires.
Rotating Types - Rotating type power sources may be divided into two classifications:
1. Motor-Generators
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 2. Engine Driven
Motor-generator types consist of an electric motor coupled to a generator or alternator
that produces the desired welding power.  These machines produced excellent welds, but due to
the moving parts, required considerable maintenance.  Few, if any, are being built today. Engine
driven types consist of a gasoline or diesel engine coupled to a generator or alternator that
produces the desired welding power.  They are used extensively on jobs beyond commercial
power lines and also as mobile repair units.  Both rotating types can deliver either AC or DC
welding power, or a combination of both.  Both types are available as constant current or
constant voltage models.
Power Source Controls - Welding power sources differ also in the method of controlling
the output current or voltage.  Output may be controlled mechanically as in machines having a
tapped reactor, a moveable shunt or diverter, or a moveable coil.  Elec- trical types of controls,
such as magnetic amplifiers or saturable reactors, are also utilized and the most modern types,
containing silicon controlled rectifiers, give precise electronic control.

(ii) Explain the three variables involved in continuous drive friction welding (8)
Friction Welding (FRW)
SSW process in which coalescence is achieved by frictional heat combined with pressure
 When properly carried out, no melting occurs at faying surfaces
 No filler metal, flux, or shielding gases normally used
 Process yields a narrow HAZ
 Can be used to join dissimilar metals
 Widely used commercial process, amenable to automation and mass production

Fig: Friction welding (FRW): (1) rotating part, no contact; (2) parts brought into contact to
generate friction heat; (3) rotation stopped and axial pressure applied; and (4) weld created.

Applications
 Shafts and tubular parts
 Industries: automotive, aircraft, farm equipment, petroleum and natural gas
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 Limitations
 At least one of the parts must be rotational
 Flash must usually be removed
 Upsetting reduces the part lengths (which must be taken into consideration in product
design)
OR
(b) (i) What are the nondestructive tests used in welding inspection? (8)
Nondestructive evaluation covers a wide group of analysis techniques used to evaluate
the properties of a material, part, product, weld, or system without causing damage. The terms
Nondestructive examination (NDE), Nondestructive inspection (NDI), and Nondestructive
evaluation (NDE) are also commonly used to describe this technology. 
NDT does not damage or permanently alter the article being inspected, which makes it a
valuable technique that can save both money and time in product evaluation, troubleshooting,
and research. Common NDT methods include ultrasonic or UT, magnetic-particle or MT, liquid
penetrant or PT, radiographic inspection or RT, visual inspection or VT, and eddy-current
testing. NDT is a commonly-used tool in forensic engineering, mechanical engineering, electrical
engineering, civil engineering, systems engineering, aerospace and aeronautical engineering, and
medical applications.

 Radiography or RT: Using radioactive isotope (x-rays or gamma rays) a film is created,
which we process in our laboratory or mobile darkroom. The results show defects which might
otherwise be invisible. A vast array of material can be examined this efficient and reliable way—
ranging from tiny electronic components to 20' freestanding concrete slabs. 

 Magnetic Particle or MT: For ferromagnetic materials such as castings, weldments, turbine
components, forgings, and machined or stamped parts, this is one of the most sensitive
nondestructive examinations. The sample is magnetized, and iron filings are applied, which
adhere to any breaks in the magnetic field. Defects too small to be visible can be further
examined with fluorescent inspection. 

 Liquid Penetrant or Dye Penetrant Inspection: Element scientists and technicians apply

dye to a sample and then examine it visually or under fluorescent light to locate defects. This is a
quick, economical NDT test method and easily set up in the field with our portable equipment. 

 Ultrasonic Inspection or UT:  With this method, NDT inspectors only need access to side
of a material. A transducer sends the ultrasound through the sample and the inner wall of a defect
surface will send the wave bouncing back. Ultrasonic testing can also measure thickness, detect
corrosion, and examine groove welds, and it’s also very portable and efficient.

 Eddy Current Inspection: A flow of periodic electrical currents in conductors called probes
creates varying electromagnetic fields. These probes are placed in close proximity to the surfaces
of the test materials, and can detect effects of processing and shaping operations during
production, as well as corrosion damage or cracking for most nonmagnetic metals and alloys.
Eddy current is a cost-effective and portable NDT method.

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  Visual Inspection or VT: Element Visual Inspectors receive specialized training to employ
a number of high-tech devices, including a Charge-Coupled Device (an advanced imaging and
color chip system) and a joystick-driven 50-foot long Steer Probe for very tight access, as well as
training on advanced computer programs that accurately measure defects, voids, pits, corrosion,
and wear, and store this information on a variety of media.

 Positive Material Identification or PMI: Positive Material Identification (PMI) is the

identification and analysis of various metal alloys by their chemical composition through
nondestructive methods. PMI can be conducted on-site or in the laboratory

(ii) Explain with neat sketch the Equipment and process of submerged arc welding (8)
Submerged arc welding
 Weld arc is shielded by a granular flux, consisting of silica, lime, manganese oxide,
calcium fluoride and other compounds.
 Flux is fed into the weld zone by gravity flow through nozzle
 Thick layer of flux covers molten metal
 Flux acts as a thermal insulator ,promoting deep penetration of heat into the work piece
 Consumable electrode is a coil of bare round wire fed automatically through a tube
 Power is supplied by 3-phase or 2-phase power lines

Fig : Schematic illustration of the submerged-arc welding process and equipment. The unfused
flux is recovered and reused.

13. (a) (i) Briefly explain about seamless rolled ring forging. (8)
Seamless rolled ring forging is typically performed by punching a hole in a thick, round
piece of metal (creating a donut shape), and then rolling and squeezing (or in some cases,
pounding) the donut into a thin ring. Ring diameters can be anywhere from a few inches to 30
feet.
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 Process Capabilities
Rings forged by the seamless ring rolling process can weigh < 1 lb up to 350,000 lbs.,
while O.D.’s range from just a few inches up to 30-ft. in diameter. Performance-wise, there is no
equal for forged, circular-cross-section rings used in energy generation, mining, aerospace, off-
highway equipment and other critical applications.
Seamless ring configurations can be flat (like a washer), or feature higher vertical walls
(approximating a hollow cylindrical section). Heights of rolled rings range from less than an inch
up to more than 9 ft. Depending on the equipment utilized, wall-thickness/height ratios of rings
typically range from 1:16 up to 16:1, although greater proportions have been achieved with
special processing. In fact, seamless tubes up to 48-in. diameter and over 20-ft long are extruded
on 20 to 30,000-ton forging presses.
Even though basic shapes with rectangular cross-sections are the norm, rings featuring
complex, functional cross- sections can be forged to meet virtually any design requirements.
Aptly named, these contoured rolled rings can be produced in thousands of different shapes with
contours on the inside and/or outside diameters. A key advantage to contoured rings is a
significant reduction in machining operations. Not surprisingly, custom-contoured rings can
result in cost-saving part consolidations. Compared to flat-faced seamless rolled rings, maximum
dimensions (face heights and O.D.’s) of contoured rolled rings are somewhat lower, but are still
very impressive in size.
High tangential strength and ductility make forged rings well-suited for torque- and
pressure-resistant components, such as gears, engine bearings for aircraft, wheel bearings,
couplings, rotor spacers, sealed discs and cases, flanges, pressure vessels and valve bodies.
Materials include not only carbon and alloy steels, but also non-ferrous alloys of aluminum,
copper and titanium, as well as nickel-base alloys.

(ii) Briefly explain flat strip rolling operation (8)

ROLLING
Process used in sheets, strips, bars, and rods to obtain products that have smooth surfaces
and accurate dimensions; most cold-rolling is performed on four-high or cluster-type rolling
mills

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 Flat Rolling
A sheet or block or strip stock is introduced between rollers and then compressed and
squeezed. Thickness is reduced. The amount of strain (deformation) introduced determines the
hardness, strength and other material properties of the finished product.
Used to produce sheet metals predominantly
OR
(b) (i) Explain hot working and cold working with their advantage and limitations (8)
Cold working
The process is usually performed at room temperature, but mildly elevated temperatures
may be used to provide increased ductility and reduced strength
For example: Deforming lead at room temperature is a hot working process because the
recrystallization temperature of lead is about room temperature.
Effects of Cold Working
Deformation using cold working results in
 Higher stiffness, and strength, but
 Reduced malleability and ductility of the metal.
 Anisotropy
Advantages
 No heating is required
 Strength, fatigue and wear properties are improved through strain hardening
 Superior dimensional control is achieved, so little, if any, secondary machining is
required
 Better surface finish is obtained
 Products possess better reproducibility and interchangeability
 Directional properties can be imparted
 Contamination problems are minimized
Disadvantages
 Higher forces are required to initiate and complete the deformation
 Less ductility is available
 Intermediate anneals may be required to compensate for the loss of ductility that
accompanies strain hardening
 Heavier and more powerful equipment is required
 Metal surfaces must be clean and scale-free
 Imparted directional properties may be detrimental
 Undesirable residual stresses may be produced
Hot working
Hot working is the deformation that is carried out above the recrystallization temperature.
Effects of hot working
 At high temperature, scaling and oxidation exist. Scaling and oxidation produce
undesirable surface finish. Most ferrous metals needs to be cold worked after hot working
in order to improve the surface finish.
 The amount of force needed to perform hot working is less than that for cold work.
 The mechanical properties of the material remain unchanged during hot working.
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  The metal usually experiences a decrease in yield strength when hot worked. Therefore, it
is possible to hot work the metal without causing any fracture.
 Quenching is the sudden immersion of a heated metal into cold water or oil. It is used to
make the metal very hard. To reverse the effects of quenching, tempering is used
(reheated of the metal for a period of time)
 To reverse the process of quenching, tempering is used, which is the reheat of the metal.
Cold-working Processes
 Squeezing
 Bending
 Shearing
 Drawing
 Presses
Classifications of Squeezing Processes
 Rolling
 Cold Forging
 Sizing
 Staking
 Staking
 Coining
 Burnishing
 Extrusion
 Peening
 Hubbing
 Riveting
 Thread Rolling

(ii) Explain with the neat sketch the process of wire drawing. (8)
Wire drawing is a metalworking process used to reduce the cross-section of a wire by
pulling the wire through a single, or series of, drawing die(s). There are many applications for
wire drawing, including electrical wiring, cables, tension-loaded structural components, springs,
paper clips, spokes for wheels, and stringed musical instruments. Although similar in process,
drawing is different from extrusion, because in drawing the wire is pulled, rather than pushed,
through the die. Drawing is usually performed at room temperature, thus classified as a cold
working process, but it may be performed at elevated temperatures for large wires to reduce
forces.

The wire drawing process is quite simple in concept. The wire is prepared by shrinking
the beginning of it, by hammering, filing, rolling or swaging, so that it will fit through the die;
the wire is then pulled through the die. As the wire is pulled through the die, its volume remains
the same, so as the diameter decreases, the length increases. Usually the wire will require more
than one draw, through successively smaller dies, to reach the desired size. The American wire
gauge scale is based on this. This can be done on a small scale with a draw plate, or on a large

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 commercial scale using automated machinery. The process of wire drawing changes material
properties due to cold working.

The area reduction in small wires is generally 15–25% and in larger wires is 20–45%.
The exact die sequence for a particular job is a function of area reduction, input wire size and
output wire size. As the area reduction changes, so does the die sequence.

Very fine wires are usually drawn in bundles. In a bundle, the wires are separated by a
metal with similar properties, but with lower chemical resistance so that it can be removed after
drawing. If the reduction in area is greater than 50%, the process may require an intermediate
step of annealing before it can be redrawn.

Commercial wire drawing usually starts with a coil of hot rolled 9 mm (0.35 in) diameter
wire. The surface is first treated to remove scales. It is then fed into a wire drawing machine
which may have one or more blocks in series.

Single block wire drawing machines include means for holding the dies accurately in
position and for drawing the wire steadily through the holes. The usual design consists of a cast-
iron bench or table having a bracket standing up to hold the die, and a vertical drum which
rotates and by coiling the wire around its surface pulls it through the die, the coil of wire being
stored upon another drum or "swift" which lies behind the die and reels off the wire as fast as
required. The wire drum or "block" is provided with means for rapidly coupling or uncoupling it
to its vertical shaft, so that the motion of the wire may be stopped or started instantly. The block
is also tapered, so that the coil of wire may be easily slipped off upwards when finished. Before
the wire can be attached to the block, a sufficient length of it must be pulled through the die; this
is effected by a pair of gripping pincers on the end of a chain which is wound around a revolving
drum, so drawing the wire until enough can be coiled two or three times on the block, where the
end is secured by a small screw clamp or vice. When the wire is on the block, it is set in motion
and the wire is drawn steadily through the die; it is very important that the block rotates evenly
and that it runs true and pulls the wire at a constant velocity, otherwise "snatching" occurs which
will weaken or even break the wire. The speeds at which wire is drawn vary greatly, according to
the material and the amount of reduction.

Machines with continuous blocks differ from single block machines by having a series of
dies through which the wire is drawn in a continuous fashion. Due to the elongation and slips,
the speed of the wire changes after each successive redraw. This increased speed is
accommodated by having a different rotation speed for each block. One of these machines may
contain 3 to 12 dies. The operation of threading the wire through all the dies and around the
blocks is termed "stringing-up". The arrangements for lubrication include a pump which floods
the dies, and in many cases also the bottom portions of the blocks run in lubricant.

Often intermediate anneals are required to counter the effects of cold working, and to
allow morefurther drawing. A final anneal may also be used on the finished product to maximize
ductility and electrical conductivity.

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 An example of product produced in a continuous wire drawing machine is telephone
wire. It is drawn 20 to 30 times from hot rolled rod stock.

While round cross-sections dominate most drawing processes, non-circular cross-sections

are drawn. They are usually drawn when the cross-section is small and quantities are too low to
justify rolling. In these processes, a block or Turk's-head machine are used.

14. (a) (i) Explain the basic nomenclature of tube bending with a simple sketch (8)
Tube bending is the umbrella term for metal forming processes used to permanently
form pipes or tubing. One has to differentiate between form-bound and freeform-bending
procedures, as well as between heat supported and cold forming procedures.
Form bound bending procedures like “press bending” or “rotary draw bending” are used
to form the work piece into the shape of a die. Straight tube stock can be formed using a bending
machine to create a variety of single or multiple bends and to shape the piece into the desired
form. These processes can be used to form complex shapes out of different types of ductile metal
tubing. Freeform-bending processes, like three-roll-pushbending, shape the workpiece
kinematically, thus the bending contour is not dependent on the tool geometry.
Generally, round stock is what is used in tube bending. However, square and rectangular
tubes and pipes may also be bent to meet job specifications. Other factors involved in the tube
bending process is the wall thickness, tooling and lubricants needed by the pipe and tube bender
to best shape the material and it is also used in different ways e.g.( tube,pipe wires).
A tube can be bent in multiple directions and angles. Common simple bends consist of
forming elbows, which are bends that range from 2 to 90°, and U-bends, which are 180° bends.
More complex geometries include multiple two-dimensional (2D) bends and three-dimensional
(3D) bends. A 2D tube has the openings on the same plane; a3D has openings on different
planes.
A two plane bend or compound bend is defined as a compound bend that has a bend in
the plan view and a bend in the elevation. When calculating a 2 plane bend you must know the
bend angle and rotation (dihedral angle).
One side effect of bending the workpiece is the wall thickness changes; the wall along the
inner radius of the tube becomes thicker and the outer wall becomes thinner. To reduce this the
tube may be supported internally and or externally to preserve the cross section. Depending on
the bend angle, wall thickness, and bending process the inside of the wall may wrinkle.

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 Tube bending as a process starts with loading a tube into a pipe bender and clamping it
into place between two dies, the clamping block and the forming die. The tube is also loosely
held by two other dies, the wiper die and the pressure die.
The process of tube bending involves using mechanical force to push stock material pipe
or tubing against a die, forcing the pipe or tube to conform to the shape of the die. Often, stock
tubing is held firmly in place while the end is rotated and rolled around the die. Other forms of
processing including pushing stock through rollers that bend it into a simple curve. For some
tube bending processing, a mandrel is placed inside the tube to prevent collapsing. The tube is
also held in tension by a wiper die to prevent any creasing during stress. A wiper die is usually
made of a softer alloy i.e. aluminum, brass to avoid scratching or damaging the material being
bent.
Much of the tooling is made of hardened steel or tool steel to maintain and prolong the
tools life. However wherever there is a concern of scratching or gouging the work piece, a softer
material such as aluminum or bronze is utilized. For example, the clamping block, rotating form
block and pressure die are often formed from the hardened steel because the tubing is not moving
past these parts of the machine. On the other hand, the pressure die and the wiping die are
formed from aluminum or bronze to maintain the shape and surface of the work piece as it slides
by.
Pipe bending machines are typically human powered, pneumatic powered, hydraulic
assisted, hydraulic driven, or electric servomotor.

(ii) Discuss super plastic forming with necessary sketches (8)

Superplastic forming is an industrial process for creating creating precise and complex
forms out of metal.
To begin with, the material must have an ultra-fine grain size. It is then heated up to
promote superplasticity. For titanium alloys e.g. Ti 6Al 4V and some stainless steels this is
around 900 °C (1,650 °F) and for aluminium alloys it is between 450–520 °C. In this state the
material is not very strong so processes that are usually used on plastics can be applied, such as:
thermoforming, blow forming, and vacuum forming; it may also be deep drawn.
The major advantage of this process is that it can form large and complex workpieces in
one operation. The finished product has excellent precision and a fine surface finish. It also does
not suffer from springback or residual stresses. Products can also be made larger to eliminate
assemblies or reduce weight, which is critical in aerospace applications. Lower strength required
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 and less tooling costs. McDonnell Douglas utilized SPF design and production technology into
the F-15 in the 1980s. They developed the production equipment and tooling technology in St.
Louis using both heated platen presses and quartz lamp tooling technology through the
leadership of Engineers Ray Kittelson, Vern Mueller, and David Rohe.
The biggest disadvantage is its slow forming rate. Cycle times vary from two minutes to
two hours, therefore it is usually used on lower volume products. Also materials must not be
superplastic at service temperatures. More recently, superplasticity has been used to form parts
for automotive applications.

OR

(b) (i) What are the different type of stretch forming ? Explain any one (8)
1. Form Block method
2. Mating die method
Mating-die Method
In this method, the blank is held in movable grippers. The blank is placed between the
lower and upper die. The lower die is kept stationary and the upper die is movable one which is
operated by hydraulic or pneumatic cylinders. First, the movable grippers are moved towards the
lower die on which only elastic deformation takes place. Next, the upper die is moved towards
the blank. When the upper die touches the blank, only elastic changes takes place. Due to
continuous stretching of the blank by the upper die, plastic flow of sheet metal takes place
between lower and upper die. When the upper die edges reach the top surface of the blank, the
stretching process is completed.
(ii) Explain with neat sketch the principle and operation of magnetic pulse forming (8)
Basic operation,
1. A large current discharge is directed through a coil. The coil has been placed inside
another shape.
2. The discharging current creates a magnetic field. In the nearby sheet of metal an
opposing magnetic field is induced. The result is that the two magnetic fields oppose and a force
moves the sheet away from the coil.
3. Over a period of time the part is deformed, often to the shape of a mandrel, or other
form.

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 Applications,
- fittings for ends of tubes
- embossing
- forming
Capacitor banks are used to accumulate charge for larger discharges.
The part is formed to a mandrel that has a negative image of the part.
The method generates pressures up to 50 Kpsi creating velocities up to 900 fps,
production rates can climb to 3 parts a second.
Applications,
- ball joint seals
- fuel pumps
- baseball bats
Generally there are three methods of magnetic forming,
- swaging
- expanding
- embossing and blanking
Swaging - An external coil forces a metal tube down onto a base shape (tubular coil).
Expanding - an inner tube is expanded outwards to take the shape of an outer collar (tubular
coil).
Embossing and Blanking - A part is forced into a mold or over another part (a flat coil) - This
could be used to apply thin
metal sheets to plastic parts.

Advantages,
- easy to control
- allows forming of metals to any material
- no contact eliminates many requirements such as lubricants, heat dissipation, surface
repair, etc.
- parts are uniform
- no tool wear
- minimal operator skill
- very strong joints
- energy efficient
- easy installation
- high production rates (typically a few seconds)
Disadvantages,

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 - complex shapes not possible
- no pressure variations over work
- limits forming pressures

15. (a) (i) What is rotational moulding? State its advantage and limitations. (8)
Rotational Molding
Rotational Molding ( BrE moulding) involves a heated hollow mold which is filled with
a charge or shot weight of material. It is then slowly rotated (usually around two perpendicular
axes) causing the softened material to disperse and stick to the walls of the mold. In order to
maintain even thickness throughout the part, the mold continues to rotate at all times during the
heating phase and to avoid sagging or deformation also during the cooling phase. The process
was applied to plastics in the 1940s but in the early years was little used because it was a slow
process restricted to a small number of plastics. Over the past two decades, improvements in
process control and developments with plastic powders have resulted in a significant increase in
usage.
Rotocasting (also known as rotacasting), by comparison, uses self-curing resins in an
unheated mould, but shares slow rotational speeds in common with rotational molding. Spin
casting should not be confused with either, utilizing self-curing resins or white metal in a high
speed centrifugal casting machine.
Advantages
Rotational molding offers design advantages over other molding processes. With proper
design, parts assembled from several pieces can be molded as one part, eliminating high
fabrication costs. The process also has inherent design strengths, such as consistent wall
thickness and strong outside corners that are virtually stress free. For additional strength,
reinforcing ribs can be designed into the part. Along with being designed into the part, they can
be added to the mold.
The ability to add prefinished pieces to the mold alone is a large advantage. Metal
threads, internal pipes and structures, and even different colored plastics can all be added to the
mold prior to the addition of plastic pellets. However, care must be taken to ensure that minimal
shrinkage while cooling will not damage the part. This shrinking allows for mild undercuts and
negates the need for ejection mechanisms (in most pieces).
In some cases rotational molding can be used as a feasible alternative to blow molding,
this is due to the similarity in product outputs, with products such as plastic bottles and
cylindrical containers, this is only effective on a smaller scale as it much more costly to blow
mold regarding a small output, and with fewer resulting products rotational molding is much
cheaper, due to blow molding relying on economies of scale regarding efficiency.
Another advantage lies in the molds themselves. Since they require less tooling, they can
be manufactured and put into production much more quickly than other molding processes. This
is especially true for complex parts, which may require large amounts of tooling for other
molding processes. Rotational molding is also the desired process for short runs and rush
deliveries. The molds can be swapped quickly or different colors can be used without purging the
mold. With other processes, purging may be required to swap colors.
Due to the uniform thicknesses achieved, large stretched sections are nonexistent, which
makes large thin panels possible (although warping may occur). Also, there is little flow of

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 plastic (stretching) but rather a placing of the material within the part. These thin walls also limit
cost and production time.
Another cost limiting factor is the amount of material wasted in production. There are no
sprues or runners (as in injection molding), no off-cuts (thermoforming), or pinch off scrap (blow
molding). What material is wasted, through scrap or failed part testing, can usually be recycled.

Limitations
Rotationally molded parts have to follow some restrictions that are different from other
plastic processes. As it is a low pressure process, sometimes designers face hard to reach areas in
the mold. Good quality powder may help overcome some situations, but usually the designers
have to keep in mind that it is not possible to make sharp threads that would be possible with
injection molding. Some products based on polyethylene can be put in the mold before filling it
with the main material. This can help to avoid holes that otherwise would appear in some areas.
This could also be achieved using molds with movable sections.
Another limitation lies in the molds themselves. Unlike other processes where only the
product needs to be cooled before being removed, with rotational molding the entire mold must
be cooled. While water cooling processes are possible, there is still a significant down time of the
mold. Additionally, this increases both financial and environmental costs. Some plastics will
degrade with the long heating cycles or in the process of turning them into a powder to be
melted.
The stages of heating and cooling involve transfer of heat first from the hot medium to
the polymer material and next from it to the cooling environment. In both cases, the process of
heat transfer occurs in an unsteady regime; therefore, its kinetics attracts the greatest interest in
considering these steps. In the heating stage, the heat taken from the hot gas is absorbed both by
the mold and the polymer material. The rig for rotational molding usually has a relatively small
wall thickness and is manufactured from metals with a high thermal conductivity (aluminum,
steel). As a rule, the mold transfers much more heat than plastic can absorb; therefore, the mold
temperature must vary linearly. The rotational velocity in rotational molding is rather low (4 to
20 rpm). As a result, in the first stages of the heating cycle, the charged material remains as a
powder layer at the bottom of the mold. The most convenient way of changing the cycle is by
applying PU sheets in hot rolled forms.
Material requirements
Due to the nature of the process, materials selection must take into account the following:
 Due to high temperatures within the mold the plastic must have a high resistance to
permanent change in properties caused by heat (high thermal stability).
 The molten plastic will come into contact with the oxygen inside the mold—this can
potentially lead to oxidation of the melted plastic and deterioration of the material's
properties. Therefore, the chosen plastic must have a sufficient amount of antioxidant
molecules to prevent such degradation in its liquid state.
 Because there is no pressure to push the plastic into the mold, the chosen plastic must be
able to flow easily through the cavities of the mold. The parts design must also take into
account the flow characteristics of the particular plastic chosen.

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 (ii) Explain briefly any two bonding methods of thermoplastics (8)
OR

(b) Explain briefly with neat sketches two commercially used methods of blow moulding for
blowing of plastics bottles and mention their specific advantages
(16)
Blow Molding
Used to make thermoplastic bottles and hollow sections. Starting material is a round
heated solid-bottom hollow tube – perform.
Perform inserted into two die halves and air is blown inside to complete the process
General steps
 Melting the resin- done in extruder
 Form the molten resin into a cylinder or tube (this tube is called parison)
 The parison is placed inside a mold, and inflated so that the plastic is pushed outward
against the cavity wall
 The part is allowed to cool in the mold and is then ejected
 The part is trimmed

The parison can be formed by

A) Extrusion process
B) Injection molding process
a) Extrusion blow molding
– Parison is formed from by forcing the plastic through an extrusion die.
– Material enters the die, flow around the mandrel so that extrudate would be cylindrical
Cape Institute Of Technology, Tirunelveli 21557
 – The die would have a hole at the center so that air could be blown into the cylinder
– In some blow molding operations, the air is introduced from the bottom through an inlet
This process can be;
– Continuous extrusion blow molding
 During the process, the extrusion runs continuously, thus making a continuous
parison.
 using multiple mold to match the mold cycle to the extrusion speed
– Intermittent extrusion blow molding
 During the process, the extruder is stopped during the time that the molding occur
 use either reciprocating screw or an accumulator system
In this system, the output of the extruder is matched by having multiple molds
which seal and blow the parison and then move away from extruder to cool and eject
In practical case, the mold cycle is longer than time required to extrude a new
parison
If the mold cycle is twice than time needed for creating a parison, a two mold
system can be used
The method is sometimes called rising mold system - system of which two or
more molds are used to mold parts from one extruder during continuous process

b) Injection Blow Molding

 The parison is formed by the injection of molten resin into a mold cavity and around a
core pin
 The parison is not a finished product, but it is subjected to subsequent step to form the
final shape
 Second step, blowing of the intermediate part in a second mold
 Because of distinct separation of the two steps, the parison made by injection molding is
called a perform
Process
 The mold is closed
 Resin is then injected to form a cylindrical part
 The mold is opened and perform is ejected
The perform can be stored until the finished blow molded is needed.
The flexibility of separating the two cycles has proven useful in manufacture of soda pop
bottle.
Comparison of extrusion and injection blow molding
Extrusion blow molding
– It is best suited for bottle over 200g in weight, shorter runs and quick tool changeover
– Machine costs are comparable to injection blow molding
– Tooling costs are 50% to 75% less than injection machine
– It requires sprue and head trimming
– Total cycle is shorter than injection (since the parison and blowing can be done using
the same machine)
– Wider choice of resin

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 – Final part design flexibility
Injection blow molding
 Best suited for long runs and smaller bottles
 No trim scrap
 Higher accuracy in final part
 Uniform wall thickness
 Better transparencies with injection blow molding, because crystallization can be better
controlled
 Can lead to improve mechanical properties from improved parison design.
Common plastics for blow molding
 HDPE (stiff bottle, toys, cases, drum)
 LDPE (flexible bottle)
 PP (higher temperature bottle)
 PVC (clear bottle, oil resistant containers)
 PET (soda pop bottle)
 Nylon (automotive coolant bottle, power steering reservoir)

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