Manufacturing Process 1 - Jun 2014

Mechanical Engg. (Semester 3)

TOTAL MARKS: 100
TOTAL TIME: 3 HOURS (1) Question 1 is compulsory.
(2) Attempt any four from the remaining questions.
(3) Assume data wherever required.
(4) Figures to the right indicate full marks. 1 (a) With a neat flow diagram, explain the steps involved in metal casting process. Also write the advantages and limitations and applications of metal casting process.(12 marks) 1 (b) What are pattern allowances? Classify and write a note on draft allowance and distortion allowance with figures.(8 marks) 2 (a) Name the base sands used in metal casting and briefly discuss the requirement of base sand.(10 marks) 2 (b) With a neat sketch, explain the working principle of Jolt & Squeeze moulding machine.(10 marks) 3 (a) Briefly explain the characteristics features of FURAN and ALKYDE type no bake moulding process.(10 marks) 3 (b) Name the centrifugal casting methods. With neat sketches explain the working of vertical and horizontal type true centrifugal casting process.(10 marks) 4 (a) With a neat sketch explain the working principle of coreless induction furnace.(10 marks) 4 (b) With a neat sketch explain the working principle of 3-phase electric arc furnace.(10 marks) 5 (a) With a neat sketch explain the principle of Laser welding process. Mention its advantages, limitations and applications.(10 marks) 5 (b) with a neat sketch explain the thermite welding process. Write the advantages and limitations.(10 marks) 6 (a) With a neat sketch explain the working principle of oxy- acetylene gas welding. Also write the flame characteristics.(12 marks) 6 (b) Explain Tungsten inert gas are welding process with figure. Mention its advantages.(8 marks) 7 Write short notes on the following:
a. HAZ in Welding
b. Shrinkage and residual stresses in welding
c. Welding defects and remedies
d. Electrodes.(20 marks) 8 (a) Distinguish between soldering and brazing. Also discuss briefly the furnace brazing process with figure.(10 marks) 8 (b) With neat sketches, explain the following types of non-destructive methods of inspection of casting and welding:
i) Eddy current testing ii) Acoustic emission monitoring.(10 marks)