1) What do you understand by barreling defect in forging?

Why it is more pronounced in hot open die forging than

cold die forging? How can you avoid barreling in hot open die forging? [10]
Sol:
a. During open die forging, as the work piece is compressed between dies it if free to move outwards from center, but
at contact point of die and work piece the frictional force acting in opposite direction opposes the outward
movement. The material moves outward from center but not at contact surfaces and takes a barrel shape. [3]

b. Non uniform temperature introduced in the material as a cold die cools the material in contact with it but at a
distance away the material is hotter thus low strength. Also, the co-efficient of friction in hot forging is more than
cold forging. [3]

c. Pre heating the die will decrease the barreling or provide the lubrication [4]

2) Which of the following part shapes cannot be manufactured using extrusion process? Justify your answer

(i) (ii) (iii)

Sol:
Shape no. ii cannot be produced as it has a non-constant cross section along all dimensions. [5]

3) A cuboid of 100 X 50 X 20 mm3 with a through hole of 4 mm diameter at the center of the 100 mm X 50 mm
surface is to be produced by sand casting process. Assume 6% shrinkage allowance, Machining allowance of 4
mm each on ABFE and ABCD surfaces respectively. Ignore all the other allowances. [15]
 i. Determine the dimensions of the pattern required for producing the casting. [8M]
ii. On which surface (s) you will recommend the core prints. Justify your recommendation. Write the surface in terms
of letters for example: AEBF [4M]
iii. Can you reuse the same core for producing the hole again? Justify in either case. [3M]

Sol:

i. Determine the dimensions of the pattern required for producing the casting.

Pattern dimensions after machining allowances = 100 mm × 54mm × 24mm

Pattern dimensions after shrinkage allowances = 106 mm × 57.24mm × 25.44mm [8M]

ii. On which surface (s) you will recommend the core prints. Justify your recommendation. Write the surface in terms
of letters for example: AEBF

ABCD and EFGH, because the function of core prints is to provide the support to the core. And the core prints will be
extended in the direction of core. [4M]

iii. Can you reuse the same core for producing the hole again? Justify in either case.

No, we cannot reuse the same core again, because to achieve the final shape of the casting/hole, core needs to be
destroyed. [3M]

4) Find the type of fit obtained if the size of hole is 25−0.000 +0.009
−0.007 mm and size of shaft is 25+0.001 mm. What will be the

type of fit if the basic size of shaft is reduced by 0.20 mm? [5]
Sol;
i. Interference fit [3M]
Maximum size of hole = 25.000 Maximum size of shaft = 25.009
Minimum size of hole = 24.993 Minimum size of shaft = 25.001
Maximum clearance = Maximum size of hole - Minimum size of shaft = 25.000 – 25.001 = -0.001
Minimum clearance = Minimum size of hole – Maximum size of shaft = 24.993 – 25.009 = -0.016
Since both the clearances are negative, it results in interference fit.
Minimum size of shaft is more than the maximum size of hole, so it is an interference fit,
 ii. Clearance fit [2M]

Maximum size of hole = 25.000 Maximum size of shaft = 24.809

Minimum size of hole = 24.993 Minimum size of shaft = 24.001
Maximum clearance = Maximum size of hole - Minimum size of shaft = 25.000 – 24.001 = 0.999
Minimum clearance = Minimum size of hole – Maximum size of shaft = 24.993 – 24.809 = 0.184
Since both the clearances are negative, it results in clearance fit.
Minimum size of hole is more than the maximum size of shaft, so it is a clearance fit,

5) In a rolling process, thickness of a strip is reduced from 5 mm to 4 mm using 250 mm diameter rolls rotating at 125
rpm. Determine the velocity of strip at neutral point in meter/sec.
Sol;
Velocity at neutral point = Velocity of roller
𝜋𝐷𝑁
Vr=
60
D= 250/1000 = 0.25 meters
N = 125 rpm
Vr = 1.636 meter/sec. [5M]

6)

i) Why does grinding process involve high specific energy as compare to other metal cutting processes? Mention two
major reasons. [4M]

i. Negative rake angle of abrasives or no control on the geometry of cutting tool [2]
ii. Ploughing or attrition wear [2]
iii. The size of chips produced in grinding is very small as compare to the chips produced by any other metal cutting
operation. Smaller the size of chips, the greater is its strength consequently grinding involves high specific energy.
S.E = Energy/Volume, Lesser volume, higher energy consumed. [2]

Any two reasons from above (i), (ii) and (iii)

 ii) Three grinding wheels P, Q and R are of same shape and size. Their specifications are given below in table.
Recommend the suitable grinding wheel (P, Q and R) from given table for following. Give suitable justification
to support your answer.

Grinding wheel Grit size Grade

P 10 Z
Q 54 C
R 500 A
a) Grinding of High Speed Steel (HSS) cutting tool
b) Grinding of Cast Iron

Sol:
a) Low MRR for hard metal: R [3]
500 grit size is fine for low MRR cut and for hard metal softest wheel or soft grade to expose new grains

b) Low MRR for hard metal: R

500 grit size is fine for low MRR cut and for hard metal softest wheel or grade to expose new grains [3]

7)
i) A XYZ company following sustainable directives is manufacturing air compressor frames, weighing over 100
kg. The number of units required by the customer are 50. Due to obsolete design, repeat orders are not expected
by the company. The company plans to use the sand casting process for manufacturing the frames. Suggest a
suitable pattern material for manufacturing the casting, Justify your selection. [3M]
ii) Due to obsolete design, company decides to redesign the above stated air compressor frame. After the redesign,
the new compressor was found to weigh around 20 kg. Compact design and lighter weight increased the demand
and a large repetitive order has been received. The company wants to invest judiciously by selecting the correct
pattern material. Suggest a suitable pattern material for manufacturing the casting, Justify your selection.
[2M]
Sol:
(i) Wood, recommended due to large weight of casting [3M]
(ii) Metal (Aluminum or Steel), More life due to higher wear resistance and can be used for repetitive
orders. [2M]
8) While cooling, a cubical casting of side 50 mm undergoes 7%, 4% and 2% volume shrinkage during the solid
state, phase transition and liquid state respectively, The volume of the metal compensated from the riser is:

Sol:
Volume of cube = 50 X 50 X 50 = 125000 mm3
 2% Liquid shrinkage = 2500 mm3
Remaining volume = 125000 -2500 = 122500 mm3
4% phase transition = 4% of 122500 = 4900 mm3
Volume of metal compensated from the riser is 2500 + 4900 = 7400 mm3 [5M]
9)
A sprue of 240 mm length has a diameter of 25 mm at its top end. The liquid metal in poring cup is maintained
up to 80 mm height. What would be the diameter of sprue at its lower end to avoid aspiration?

ht = 80+240 = 320 mm, hc = 80 mm

𝐴2 √320
= =2
𝐴3 √80
𝐷2 2
= 2, D2= 25 mm
𝐷3 2

25𝑋25
𝐷3 = √ = 17.677 𝑚𝑚 [5]
2

10)

There is a crack in the silencer of a car and needs to be repaired by welding without detaching it from the car. The
silencer is made of mild steel and has an inner diameter of 70 mm and an outer diameter of 73 mm. Assume that; AC
arc welding, DC arc welding and Gas welding processes are available to the operator in a workshop. [5M]

i. Recommend the most suitable welding process for repairing the silencer. Justify your answer.

ii. Recommend the most suitable welding position to be used to repair the silencer. Justify your answer.

iii. Recommend the most suitable welding technique to be used to repair the silencer. Justify your answer.

Sol:

i) Suggest the most suitable joining method (s) for repairing the silencer. Justify your answer.
Ans: Gas welding, because the thickness of the metal sheets to be weld is less than 4 mm. [2]
 ii) Suggest the most suitable welding position (s) to be used to repair the silencer.
Ans: Overhead welding position because the silencer needs to be repaired without detaching it from the
vehicle (car). [2]

iii) Suggest the most suitable welding technique (s) to be used to repair the silencer.
Ans: Forward/forehand welding technique. Because less heat concentration required on the weld. [1]

11)

Write a CNC part program using metric units with absolute dimensions to engrave the geometry as given in Fig.1,
symmetrically on a cubical block (Fig. 2). The workpiece material is mild steel and all the dimensions are in mm. The
engraving should start from point ‘O’ and follow the path ‘O-A-B-C-D-O’. [10M]
The other details are as follows:

 Engraving depth is 1.5mm.

 The cutting operation should be done in a wet environment with a spindle speed of 1500 rpm and feed rate of 100
mm/min.
 Cutting operation is performed using end milling cutter on a CNC milling machine.
 AD should be parallel to the side PQ, and P should be adopted as origin.

Sol;
G54 G21 G98 G40; mm/min
G28 G91 Z0.0; at top
G28 G91 X0.0; Incremental with G28
G28 G91 Y0.0;
T (TOOL NO.); Ignore
M06;
M03 S1500;
M08;
G90; Important, not written then zero marks
G43 H1 Z10.0; ignore 2 Marks

G00 X0.0 Y0.0 Z5.0; ignore

G00 X20.0 Y20.0;
G01 Z-1.5 F100; [1] mark deduct, if not written
G01Y4.0; [1]
G03X36.0Y20.0 R16.0; [1]
G01 X4.0; [1]
G02 X20.0 Y36.0 R16.0; [1]
G01 Y20.0; [1]
G00 Z5.0; 6 Marks

G28 G91 Z0.0;

G28 G91 X0.0;
G28 G91 Y0.0;
M05; spindle stop
M09; coolant stop
M30; program stop 2 marks

Part program beginning and ending is incorrect.