MECHANICAL ENGINEERING DEPARTMENT

NATIONAL INSTITUTE OF TECHNOLOGY, ROURKELA-8

END- SEMESTER EXAMINATION, June 2021
SESSION: 2020-2021, SEMESTER: SPRING
B.TECH.: 4th SEMESTER, Mechanical Engineering
SUBJECT: Primary Production Processes (ME-2202) (ME)
FULL MARKS: 50
Duration of Examinations: 2 Hours It contains 2 pages and 4 questions
Answer ALL Questions
All parts of a question (i, ii, iii etc) should be answered at one place.
Answer should be brief and to-the-point and be supplemented with neat sketches.
Any missing data or wrong data may be assumed suitably giving proper justification.

1. Solve (any four) 4x4 30 minutes

i) A copper block of size 200x100x50 mm is to be made by casting. Find the dimensions of the wooden
pattern assuming machining allowance of 1 mm on top surface only, shaking allowance of 2.0 mm on
length and width, shrinkage allowance of 5% and taper allowance of 3 degree.
ii) An aluminum billet of 50 mm thickness is to be decreased to thickness of 30 mm in a rolling process by
number of passes. The radius of roll is 500 mm, Find the minimum number of passes required, if bite angle
is 10 degree.
iii) A hole of 30mm diameter is to be made on a copper sheet of 10 mm thickness by punching. The shear
strength of the material is 250 MPa. What is the cutting force required? Find the diameter of punch and die
if the clearance is 2 mm.
iv) The arc length-arc voltage characteristic of a DC arc welding is given by V=10+40L where V is the arc
voltage and L is the arc length in mm. The static V-I characteristic of the power source is given by a straight
line with open circuit voltage (OCV) of 90 volts and short-circuit current of 400 A. Determine the optimum
arc length for maximum power.
v) A cylindrical steel block of diameter 30 mm and height 60 mm is to be forged by a press to a height of 20
mm. True stress-strain curve of the steel follow  = 350 ε0.38MPa, µ=0.0. If the capacity of the press is
400 kN, is it possible to forge the work piece?
 MECHANICAL ENGINEERING DEPARTMENT
NATIONAL INSTITUTE OF TECHNOLOGY, ROURKELA-8
END- SEMESTER EXAMINATION, June 2021
SESSION: 2020-2021, SEMESTER: SPRING
B.TECH.: 4th SEMESTER, Mechanical Engineering
SUBJECT: Primary Production Processes (ME-2202) (ME)
FULL MARKS: 50
Duration of Examinations: 2 Hours It contains 2 pages and 4 questions
Answer ALL Questions
All parts of a question (i, ii, iii etc) should be answered at one place.
Answer should be brief and to-the-point and be supplemented with neat sketches.
Any missing data or wrong data may be assumed suitably giving proper justification.

2. A. Practical Application: Describe how to manufacture the following components: (any five) 1x5
Total 30 minutes

i) Big sewage/drain pipes. ii) Turbine blades.

iii) Self-lubricated Babbitt bearings for automobiles iv) Head of the bolt
v) Daily use aluminum utensils vi) collapsible tubes like that for toothpaste and shaving cream.
B. Industrial problem: Propose a suitable Solution (any five) 1x5
vii) To weld Railway lines at remote areas. viii) The sheets manufactured by rolling are wavy
ix) Wrinkles are found on the flange of a cup manufactured by deep drawing x) Found cracks at
corner points of a casted wheel xi) Pitting marks are observed on the surface of a forged wrench
xii) When two mild steel flat are welded by single V butt joint, found to be curved upward.
 MECHANICAL ENGINEERING DEPARTMENT
NATIONAL INSTITUTE OF TECHNOLOGY, ROURKELA-8
END- SEMESTER EXAMINATION, June 2021
SESSION: 2020-2021, SEMESTER: SPRING
B.TECH.: 4th SEMESTER, Mechanical Engineering
SUBJECT: Primary Production Processes (ME-2202) (ME)
FULL MARKS: 50
Duration of Examinations: 2 Hours It contains 2 pages and 4 questions
Answer ALL Questions
All parts of a question (i, ii, iii etc) should be answered at one place.
Answer should be brief and to-the-point and be supplemented with neat sketches.
Any missing data or wrong data may be assumed suitably giving proper justification.

3. Answer all questions in brief (any Ten) 1.5x10 30 minutes

I. What is the use of chill and chaplets in casting?

II. Difference between forehand and backhand gas welding process?
III. What is flux? Why it is essential to use in welding?
IV. Essential good properties of molding sand.
V. Fettling process for casting.
VI. What is a non-transferred type plasma arc welding? What is its advantage?
VII. Differentiate between conventional strain and true-strain
VIII. Steps followed in investment casting.
IX. What are specific merits of cold working over hot working?
X. Differentiate between coining and embossing.
XI. What is ironing in a sheet metal operation?
 MECHANICAL ENGINEERING DEPARTMENT
NATIONAL INSTITUTE OF TECHNOLOGY, ROURKELA-8
END- SEMESTER EXAMINATION, June 2021
SESSION: 2020-2021, SEMESTER: SPRING
B.TECH.: 4th SEMESTER, Mechanical Engineering
SUBJECT: Primary Production Processes (ME-2202) (ME)
FULL MARKS: 50
Duration of Examinations: 2 Hours It contains 2 pages and 4 questions
Answer ALL Questions
All parts of a question (i, ii, iii etc) should be answered at one place.
Answer should be brief and to-the-point and be supplemented with neat sketches.
Any missing data or wrong data may be assumed suitably giving proper justification.

4. A. Draw free hand sketches (any five) 1x5 Total 30 minutes

i) Hot chamber die casting.

ii) Cross section of a sand mould which is ready for pouring, and label the various parts.
iii) Different zones of carburizing flame used in oxy-acetylene gas welding.
iv) Different components of an ultrasonic welding set-up.
v) 3 stand 4 high tandem/ continuous rolling mill.
vi) Show the flash and gutter in a forging die set-up.

B. Know How/Mechanics knowledge Test: Describe with diagram (any four) 1x4
vii) Difference between Brazing and soldering?
viii) How Oxy-acetylene cutting torch is different from welding torch? Show by diagram.
ix) Why parts manufactured by forming processes have better mechanical properties than produced
by casting and machining? Explain by a diagram.
x) Show the sequence of forging operations to manufacture a crane hook.
xi) Shear angle is provided on which part of the punching operation? How it is specified?
xii) What is roll bending defect? How it can be minimized.

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