4128122, 956 AM. END Semester Qu: n Paper - Google Docs Roll Number: Indian Institute of Technology Jodhpur Semester Exam Course : Manufacturing Processes Time: 02 Hour; Maximum marks: 80 Name of Course Instructor: Dr. Chandan Pandey Section A [20 marks} 1. Equal amounts of liquid metal at the same temperature are poured into three molds made of steel, copper and aluminum. The shape of the cavity is a eylinder with 15 mm diameter, The size of the molds are such that the outside temperature of the molds do not increase appreciably beyond the atmospheric temperature during solidification. ‘The sequence of solidification in the mold from the fastest to slowest will be (Thermal conductivities of steel, copper and aluminum are 60.5, 401 and 237 Wim-K, respectively. Specific heats of steel, copper and aluminum are 434, 385 and 903 J/kg-K, respectively. Densities of stel, copper and aluminum are 7854, 8933 and 2700 kg/m’, respectively) ‘a. Aluminium-steel-copper b, Steel-copperaluminium ¢. Aluminium-copper-stee! 4. Copper-aluminium-steel 2. Match the casting defects (Group A) with the probable causes (Group B): Group A Group 8 [P:Hot tears |: Improper fusion of two streams of liquid metal \Q: Shrinkage 2: Low permeability of the sand mould IR: Blow holes: Volumetric contraction both in liquid and solid stage| [5: Cold Shut fs: Differential cooling rate PAQ3R2S4 P4Q3R281 3. To reduce the mold erosion in sand casting: a, Spruc is tapered b. Cylindrical sprue is used . Sprue base well is provided 4. Runner is made of trapezoidal 4, ‘The welding process preferred in ship industries is: a MMAW SAW ©. GTAW 4.GMAW 5. In.an are welding process, the voltage and current are 25 V and 300 A, respectively. The are heat transfer efficiency is 0.85 and the welding speed is 8 mm/sec. The net heat input (in Jimm) is: a, 1106 ».797 6.937 4. 1180 6. Match the correct pairs: Iitpstidocs. google.comidocumentat-VKi7CQC tcyaodF CGQJgvrSmssBQD¥ghOPBNUO_hisiedt ua4128122, 056 AM END Semester Quastion Paper - Google Docs Processes Characteristies/Applications P. Friction welding 1. non—consumable electrode (Q. Gas metal are welding 2, joining of thick plates R. Tungsten inert gas welding 3. consumable electrode wire S. electrosiag welding 4. joining of cylindrical dissimilar materials a. PA QSR2S-1 b. PA Q2R3 S41 ©. P2Q3R4 S-1 4 P2Q4R1S3 7. The following is always a cold working process: a. Rolling b. Extrusion ©. Forging 4. Wire drawing 8. The operation is to be used to remove the burr produced during the blanking operation is: a, Nibbling b. Trimming ©. Notching 4. Shaving 9. A steel wite of a diameter 10 mm is drawn through a die ata speed of 0.5 mm/sec to reduce the diameter by 20%. The yield stress ofthe material is 600 MPa. Neglect the friction and strain hardening, calculate the power (kW) required forthe drawing process: a4 bo 6.28 13.45 10. A solid cylindrical stainless steel workpiece of 200 mm diameter and 150 mm height is reduced by 50% in hncight using a flat die forging operation. Assuming the flow stress as 1000 MPa and coefficient of friction 10 be 0.2, the forging force (KN) atthe end of stoke willbe: a 208 b.31 6.254 4786 Section B [20 marks} ‘Attempt any five questions: Justify the following: Splash core and skim bomb help to enhance the quality of cast product, 1 2, Hot chamber die casting is restricted to zine-base alloys, 3. Welding position play an important role in the selection of SMAW electrode? 4, Brazing process is preferred to joining the martial having Metallurgical ineompatibility 5. Difficult to select the proper value of the flow stress in forming process. 6. Wrinkling is more common in the deep drawing process performed with blank holder force. Section C [20 marks) Attempt any four questions: 1. iseuss feeding distance and their component, 2. For the casting shown in Figure, which is made of cast iron, find out the choke area, Iitpstidocs. google.comidocumentat-VKi7CQC tcyaodF CGQJgvrSmssBQD¥ghOPBNUO_hisiedt aie4128122, 956 AM. END Semester Qu: Given: Pouring time for grey cas irom: Grey cast irom masses than 450 Pourimg time (= K(L AL +E) Where, KeFuty of iron in inches ‘Tis the evetage section thickness and Kis mass ofthe cating in Ke, Grey cat iron, mass greater than 450 kg: Pourimg time () = K(1.236 + Ze y\Ws Given density ofthe solid cast iron material: 786+10* ke/mm’, the density ofthe liquid metal: 6.9010 kgimm, fluidity length=22 inches, efficiency factor (C)=D.73. 3, Write short notes on the following; Cold shut, Tungsten inclusion, and Zipper crack. 4, Calculate the length of sheet required for making the component shown in Figure. 5. Determine the blanking force to cut a blank 28 mm wide and 34 mm long from a 1.6 mm thick strip ‘The ultimate shear stress of the material is 450 MPa, Also, determine the work done ifthe percentage penetration is 24%, 6. An aluminum alloy of hot extruded at 400 °C through square dies without lubrication from 135 mm diameter to 45 mm diameter. The extrusion speed is 48 mm/sec. The flow stress of the material at a given temperature is 250 MPA. The length of the billet is 400 mm, Determine the extrusion load if the cooficient of fiction is 0.1, Section D [20 marks} Attempt any two questions: L, Determine the dimension of a cylindrical riser to be used for casting as aluminum cube of sides 15 em. ‘The volume shrinkage of sluminum during solidification is 6.5%. 2. Two steel shects of thickness 1 mm are resistance welded in a projection welding with a welding ceurrent of 30000 A for 0.005 sec. The effective resistance of the joint can be taken as 100 micro ohms. Iitpstidocs. google.comidocumentat-VKi7CQC tcyaodF CGQJgvrSmssBQD¥ghOPBNUO_hisiedt4128122, 056 AM END Semester Quastion Paper - Google Docs The joint can be considered as a cylinder of S mm in diameter and 1.5 mm in height, Density of steel is 0.00786 g/mm! and the heat required for melting steel be taken as 10 J/mm’. Find out the efficiency of the process, heat loss to surrounding and heat utilized for joining, 3. Describe the following forming processes with a neat sketch: Embossing, Bending. lanking, Piercing, Nibbling, Notching, Iitpstidocs. google.comidocumentat-VKi7CQC tcyaodF CGQJgvrSmssBQD¥ghOPBNUO_hisiedt 48