MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)
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SUMMER– 19 EXAMINATION
Subject - MANUFACTURING PROCESSES Model Answer Subject Code: 22446
Important Instructions to examiners:
1) The answers should be examined by key words and not as word-to-word as given in the model answer
scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try to assess the
understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more Importance (Not
applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the figure. The
figures drawn by candidate and model answer may vary. The examiner may give credit for any equivalent
figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant values
may vary and there may be some difference in the candidate’s answers and model answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant answer
based on candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.

Q. Sub Marking
Answer
No. Q N. Scheme

a List types of chips produced in machining process. 2 marks to

list types
The various types of chips produced in machining process are as follows:

1. Continuous chips: According to its name, continuous chips have a continuous

segment. .
1
2. Discontinuous chips or segmental chips: According to its name, this chips
form in segment.

3. Continuous Chips with built up edge: This type of chip is same as the
continuous chips except a built edge is form at the face of tool.

b List any four accessories used on lathe. ½ mark each

for any four
The various accessories used in lathe are as follows. accessories

1) Lathe centers 2 marks

2) Carriers or driving dog

3) catch plates

4) Chucks

5) Face plates

6) Angle plates

7) Mandrels

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8) Rests

c Define Feed and speed in shaping machine 1 mark for

1) Feed: Feed (S) is the relative movement of the work or tool in a direction each
perpendicular to the axis of reciprocation of the ram per double stroke. It is expressed definition
in mm per stroke. 2 marks
2) Speed: In a shaper, the cutting speed is the speed at which the metal is removed by
the cutting tool in a period of one minute.

d List any four materials used for pattern making. ½ mark each
The various types of materials used are as follows: for any 4
types
1. Wood
2. Metal. 2 marks

3. Plastic.
4. Plaster.
5. Wax.
e List any four casting defects. ½ mark each
for any 4
The various types of casting defects are as follows:
defects
1. Gas Porosity: Blowholes, open holes, pinholes.
2 marks
2. Shrinkage defects: shrinkage cavity.
3. Mold material defects: Cut and washes, swell, drops, metal penetration, rat
tail.
4. Pouring metal defects: Cold shut, misrun, slag inclusion.
Metallurgical defects: Hot tears, hot spot.

f State the applications of rolling. Any four

application ½
Applications of rolling are as follows:
mark each
1. Concrete reinforcing bars.
2 marks
2. Plates.
3. Wire rods.
4. Sheet and strip.
5. Rails.
6. Piping and tubes.
7. Body panels.
8. Construction materials.
g State the applications of TIG welding. 2 marks
The applications of TIG welding are as follows: Any Two
1. Mostly used to weld aluminum and aluminum alloys. application

2. It is used to weld stainless steel, carbon base alloy, copper base alloy, nickel
base alloy etc.

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3. It is used to welding dissimilar metals.
4. It is mostly used in aerospace industries.

a Write specifications of slotting machine. Detailed

specifications

4 marks

b Explain any four properties of Moulding sand. Any 4

explanation
1. Porosity: Molten metal always contain a certain amount of dissolved gases,
which are evolved when the metal freezes the molten metal coming in contact with 1 mark each

the moist sand , generates steam or water vapour. If these gases and water vapour 4 marks
evolved by moulding sand do not find opportunity to escape completely through the
mould they will form gas holes and pores in the casting. The sand must, therefore,
be sufficiently porous to allow the gases or moisture present.
2. Strength: This is the ability of sand particles to stick together. Insufficient
strength may lead to a collapse in the mould or its partial destruction during
conveying, turning over or closing. The mould may also be damaged during pouring
by washing of the walls and core by the molten metal. The strength of moulding
sand must, therefore, be sufficient to permit the mould to be formed to the desired
shape and to retain this shape even after the hot metal is poured in the mould.
3. Collapsibility: After the molten metal in the mould gets solidified, the sand
mould must be collapsible so that free contraction of the metal occurs, and this
would naturally avoid the tearing or cracking of the contracting metal.
4. Adhesiveness: The sand particles must be capable of adhering to another body,
i.e. they should cling to the sides of the moulding boxes. It is due to this property
that the sand mass can be successfully held in a moulding box and it does not fall
out of the box when it is removed.
5. Cohesiveness: This is the ability of sand particles to stick together. Insufficient
strength may lead to a collapse in the mould or its partial destruction during
conveying, turning over or closing. The mould may also be damaged during pouring
by washing of the walls and core by the molten metal. The strength of moulding
sand must, therefore, be sufficient to permit the mould to be formed to the desired
shape and to retain this shape even after the hot metal is poured in the mould.
6. Refractoriness: The sand must be capable of withstanding the high temperature

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of the molten metal without fusing. Moulding sands with a poor refractoriness may burn
on to the casting. Refractoriness is measured by the sinter point of the sand rather than
its melting
c Compare between Hot rolling and Cold rolling. Any 4 correct
comparison
Sr
Hot rolling Cold rolling
No. 1 mark each

4 marks
Metal is fed to the rolls after being
Metal is fed to the rolls when it is below
1 heated above the recrytallization
the recrytallization temperature.
temperature.

In general rolled metal does not The metal shows the working hardening
2
show work hardening effect. effect after being cold rolled.

Co-efficient of friction between

two rolls and the stock is higher; it Co-efficient of friction between two rolls
3
may even caused shearing of the and the stock is comparatively lower.
metal in contact with rolls.

Experiment measurements are Experiment measurement can be

4
difficult to make. carried out easily in cold rolling.

Heavy reduction in area of the

5 Heavy reduction is not possible.
work piece can be obtained.

Mechanical properties are

improved by breaking cast
Hotness increased excessive cold
structure are refining grain sizes
working greatness crackers ductility of
below holes and others, similar
6 metal reduction. Cold rolling increased
deformation in ingot (get welded)
the tensile strength and yield strength of
and or removed the strength and
the steel.
the toughness of the job should
increases.

Rolls radius is generally larger in

7 Rolls radius is smaller.
size.

Very thin sections are not

8 Thin sections are obtained.
obtained.

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Hot roll surface has (metal oxide)
The cold rolled surface is smooth and
9 on it, this surface finish is not
oxide free.
good.

Hot rolling is used un ferrous as

well as non ferrous metals such Cold rolling is equally applicable to
10 as industries for steel, aluminum, both plain and alloys steels and non
copper, brass, bronze, alloy to ferrous metals and their alloys.
change ingot into slabs.

Hot rolling is the father of the cold

11 Cold rolling follows the hot rolling.
rolling.

d Explain with neat sketch the working principle of MIG.

In metal-arc inert gas welding the Weld area is shielded by an effectively inert 2 marks for
atmosphere of argon, helium, carbon dioxide, or various other gas mixtures . The principle 2
consumable bare Wire is fed automatically through a nozzle into the Weld arc by a marks for
Wire-feed drive motor . In addition to using inert shielding gases, deoxidizers usually sketch
are present in the electrode metal itself in order to prevent oxidation of the molten-weld
puddle. Multiple-weld layers can be deposited at the joint.

Figure: Principle of MIG welding

a Single point Cutting tool signature 04 marks for
correct
The shape of a tool is specified in a special sequence and this special sequence is
explanation
called tool signature. The tool signature is given below

(i) Back rake angle

(ii) Side rake angle
3
(iii) Clearance or End Relief angle
(iv) Side Relief angle
(v) End cutting edge angle
(vi) Side cutting edge angle
(vii) Nose radius

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A typical tool signature of single point cutting tool is 0-7-6-8-15-16-0.8. Here this tool
signature indicates that the tool has 0, 7, 6, 8, 15, 16 degree back rake, side rake, end
relief, side relief, end cutting edge, side cutting edge angle and 0.8 mm nose radius.

b Since useful work is done only during the forward stroke of ram, the mechanism driving 02 marks for
sketch, 02
the ram is so designed that the return stroke is completed in much less time than the
marks for
forward stroke. The slotted lever quick return mechanism is illustrated in Figs. a and b explanation
The crank AB (of adjustable length R) rotates with a uniform angular speed. The crank
pin B is in the shape of a die block which is free to slide inside the slot in the slotted
lever OBC. This slotted lever is pivoted at O and the other end C is connected to the
ram by a short link arm as shown in
Fig. (a). When the crank AB rotates clockwise from position AB1 to AB2, the ram
moves forward from left to right and when it rotates from position AB2 to AB1 the ram
returns back to its original position.
Clearly the time taken to complete forward stroke is proportional to angle (refer to
Fig. (b))and the return stroke is completed in less time which is proportional to angle .

c Safety practices in foundry: Any four

points 01
1. Even trace amounts of MOISTURE and MOLTEN METAL don't mix; Steam mark each
explosions are the cause of death in foundries.

2. NEVER put water on a metal fire. This can cause a HUGE EXPLOSION

3. Have a DRY pile of sand and a shovel ready to put out fires or to control metal spills.

4. Have a sand bed under all areas. The sand bed should be at least 3 inches thick.
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This will help in containing metal spills and will help protect flooring.

5. Never pour over wet ground. Remember, even TRACE AMOUNTS of MOISTURE
can cause EXPLOSIONS.

6. Molten metal spilled on concrete will cause the concrete to explode. Use a thick
sand bed over concrete.

7. Always use clean metal as feedstock. Combustion residues from some lubricants
and paints can be very toxic.

8. Always operate in a well-ventilated area. Fumes and dusts from combustion and
other foundry chemicals, processes and metals can be toxic.

9. Use a NIOSH rated dusk mask. Dusts from sand, parting dusts and chemicals can
be hazardous or cancer causing. Protect your lungs.

10. Wear safety gear, This includes, Leather shoes , Fireproof apron ,Foot and leg
protection, Proper gloves, wire mesh face shield, Safety glasses , Cotton baseball hat.

11. Never use a crucible that has been damaged or dropped. It's just not worth the
risk. Imagine what would happen if a white-hot crucible of brass crumbled as you were
carrying it.

12. Always charge crucibles when cold. Adding metal to a hot crucible is really
dangerous. If there is moisture on the metal, even just a haze, the metal can cause the
entire contents of the crucible to explode.

13. Spilled molten metal can travel for a great distance. Operate in a clear work area.

14. use Long-handled pliers (or tongs) and rod. The pliers are designed for adding
things to the crucible and adjusting coals, etc. The rod is used for mixing the contents
of crucible and move dross to the side just before pouring.

15. Think about what you are doing at all times. Focus on the job at hand and the next
step. Have all moves planned and rehearsed prior to any operation.

16. Educate yourself beforehand and always be careful of your own and bystander
safety.

d Differentiate between soldering and brazing An four

points 01
S. mark each
No. Soldering Brazing
It is used in electrical industries
to joint capacitor, resistor, wire It is used to mechanical industries to
1. etc. to the electronic plate. joint different metals.
Brazing is done at temperature
Soldering is done at temperature above 450C but below the critical
2. below 200 C. temperature of metal.
These joints are weaker than
3. brazing joints. It forms stronger joint.

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In soldering an alloy of lead and In brazing an alloy of copper and zinc
4. tin is used known as solder. is used as filler metal.
It does not need a special
5. training to soldering. It needs special trading.
6. It is a cheaper process. It is a costly process.
Soldering does not need to This process needs preheating of
7. preheat of base metal. base metal.
It is used to joint electronics It is used in automotive industries
8. component. and pipe fitting.
It is not so easy for automation
This process is very flexible and except automation is done at
9. easy to automate. automotive industries.
a 02 marks for
sketch, 02
marks for
labeling

b Types of slotting machine:- 02 marks for

classification,
1. Puncher slotter 2. Precision slotter 3. Production slotter 02 marks for
principle
Working Principle of Slotting machine:-
The slotting machine is a reciprocating machine tool in which, The vertical slide holding
the cutting tool is reciprocated by a crank and connecting rod mechanism, The job, to
be machined, is mounted directly or in a vice on the work table. Like shaping machine,
in slotting machine also the fast cutting motion is imparted to the tool and the feed
motions to the job. In slotting machine, in addition to the longitudinal and cross feeds,
a rotary feed motion is also provided in the work table.

c Injection Molding produces plastic parts by forcing molten material into a mold 02 marks for
where it cools and hardens. The molded shape produced is a reverse image of the sketch, 02
mold tool. Injection molding is low cost moulding for simple and complex parts. The marks for
explanation
pressure of injection is high, dependant on the material being processed.

Injection Molding is commonly used for thermoplastics. The powder compound

is first heated to drive moisture and then feed into the hopper. When the rain is
drawn back, some of the powder drops into the chamber. Close the mold and ram is
moved forward applying pressure behind the powder. This compresses the material
and forces it forward through thin space left around the heated torpedo. The
material will come in contact with heated source and solution. The material during
heating in the chamber rises the temperature between 1750 c to 2750 c. This heated

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material is forced into the mold then the mold is cooled and it is opened. The part is
knocked out by knockout pins.

Figure: Injection Moulding

d Types of rolling mills and its applications:- 02 marks for
types any
(1) Two-high rolling mill: used in blooming and slabbing mills four (1/2 mark
for each
(2) Three-high rolling mill: used for making plates or sections. type,) 02
marks for
(3) Four-high rolling mill: It is used for both hot and cold rolling of wide plates and application
sheets. (1/2 mark
(4) Cluster rolling mill: This mill is used for rolling stainless steel and other high each ,)
strength steel sheets of thin gauge.

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e 02 marks for
Welding Defects list any four
defects (1/2
Welding defects Explanation and mark each )02
causes marks for
1. Cracks Cracks occur when localized stresses exceed the causes (1/2
ultimate tensile strength of material. These stresses are mark each )
developed due to shrinkage during solidification of weld
metal. Cracks may be developed due to poor ductility of
base metal, high sulpher and carbon contents, high arc
travel speeds i.e. fast cooling rates, too concave or
convex weld bead and high hydrogen contents in the
weld metal.
2. Porosity Porosity results when the gases are entrapped in the
solidifying weld metal. These gases are generated from
the flux or coating constituents of the electrode or
shielding gases used during welding or from absorbed
moisture in the coating. Rust, dust, oil and grease
present on the surface of work pieces or on electrodes
are also source of gases during welding.
3. Lack of Fusion Too fast a travel, Incorrect welding technique,
Insufficient heat
4.Slag Inclusion Slag from previous runs not being cleaned away,
Insufficient cleaning and preparation of the base metal
before welding commences.
5. Undercuts Too fast a travel, Bad welding technique, Too great a
heat build-up.

a Explain with neat sketch following drilling operation: 02 marks for

each (01 Mark
(i) Reaming for
description,
The process of enlarging the hole is called reaming. A reamer is a type of rotary 01 Mark for
cutting tool used in metalworking. Precision reamers are designed to enlarge the size of figure)
a previously formed hole by a small amount but with a high degree of accuracy to leave
smooth sides. There are also non-precision reamers which are used for more basic
enlargement of holes or for removing burrs.

(ii) Boring operation:

In machining, boring is the process of enlarging a hole that has already
been drilled (or cast) by means of a single-point cutting tool , such as in boring a gun

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barrel or an engine cylinder. Boring is used to achieve greater accuracy of the diameter
of a hole, and can be used to cut a tapered hole. Boring can be viewed as the internal-
diameter counterpart to turning, which cuts external diameters.

Boring operation

(iii) Counter sinking:

Countersinking is the operation of making a cone shaped enlargement of the end of a
hole to provide a recess for a flat head or countersink rivet fitted into the hole. The tool
used for countersinking is called a countersink. Standard countersinks have 60, 82 or
90 included angle and the cutting edges of the tool are formed at the conical surface.

Countersinking operation

b Types of pattern: Any Six types

03 Marks (1/2
1. Single piece pattern mark each), 3
marks for
2. Split pattern
procedure
3. Match plate pattern
4. Cope and drag pattern
5. Gated pattern
6. Loose piece pattern
7. Sweep pattern
8. Skeleton pattern
9. Segmental pattern
10. Shell pattern
11. Built up pattern
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12. Boxed up pattern
13. Lagged up pattern
14. Left and right hand pattern

Procedure for Pattern Construction: The pattern part of casting process, it is replica of
the object to cast, and used to prepare the mold cavity into molten material poured
during the casting process. The sand casting pattern making is duplicate component of
molding. The design patterns material such as wood, metal or plastic and more. The
sand casting pattern making with same shape of part, not exactly in same size.
Because of shrinkage provide when it convert from liquid form into solid state. So the
cavity made in little large than the exact actual part required. There should be some of
allowances with in machining and finishing process. It required to modification are
addition of pattern allowances. If the hollow casting provided, the core are used to
create the cavity in finished part. The quality of casting depends on the design patterns
material and construction. Sweep pattern sand casting is mainly for circular part make.

c Types of Press Forging Operation: Any 3 , 02

marks each
1) Cold forging: Forging is carried out at or near room temperature (below the (01 mark for
recrystallization temp.) of the metal. Carbon and standard alloy steels are most sketch 01
commonly cold forged. Cold forging is generally preferred when the metal is already a mark for
soft, like aluminum. This process is usually less expensive than hot forging and the end explanation)
product requires little or no finishing work.

2) Hot forging: Forging is carried out at a temperature above the recrystallization

temperature of the metal. The recrystallization temperature is defined as the
temperature at which the new grains are formed in the metal. This kind of extreme heat
is necessary in avoiding strain hardening of the metal during deformation.

3) Closed-die forging : Forging in which the material is fully constrained in the cavity
created by the upper and lower die halves. It allows more accurately shaped parts to

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be formed, higher interface pressures required, Requires very accurate control of
material volume and proper die design. Closed-die forging is a form of impression-die
forging, which does not depend on flash formation to achieve complete filling of the die.
Material is deformed in a cavity that allows little or no escape of excess material, thus
placing greater demands on die design.

4) Open-die forging: Forging in which the flat dies of simple shape are used to allow the
material to freely deformed in lateral directions of applied load. open die forging is only
suitable for simple shapes for its less dimensional accuracy, there is high requires on
the skill of operators, the dies of open die forgings are simple and less expensive,
which is simplest of all the forging operations.

a Types 02
Taper tuning is performed, when a specific taper is required on work-piece. This can be
Marks ½ mark
performed by following four methods: each(any four
types) , Any
1. Form tool method one explain
04 Marks (02
2. Tail-stock set over method marks for
3. Compound rest method sketch 02
6 marks for
4. Taper turning attachment method
explanation)

Explanation:

1. Form tool method:

This is one of the simplest methods to produce short taper. To the required
angle the form is grounded and used. The tool is fed perpendicular to the
lathe axis, when the work piece rotates.

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3. Compound rest method:

Generally short and steep taper are produced using this method. In this
method the work piece is held in the chuck and it will be rotated about the
lathe axis. The compound rest is swiveled to the required angle and then it
will be clamped in position.

4. Taper turning attachment method:

In this method by using bottom plate or bracket, a taper turning attachment is attached
to the rear end of the bed. It has a guiding bar which is usually pivoted as its center.
The guiding bar has the ability to swing and it can be set in any required angle. It has
graduations in degrees. It has a guide block which connects to the rear end of the cross
slide and it moves on the guide bar. The binder screw is removed, before connecting
the cross slide, hence the cross slide is free from the cross slide screw.

b Calendaring Process of plastic manufacturing: 3 Marks

Explanation,
Calendaring is a process in which heat and pressure are applied to a fabric by passing it 03 marks Fig
between heated rollers, imparting a flat, glossy, smooth surface. During calendaring
process rolls of the materials are passed between several pairs of heated rollers, to give

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shiny surface. Luster (i.e. finishing) increases when the degree of heat and pressure is
increased. Calendaring is applied to fabrics in which a smooth, flat surface is desirable,
such as most cotton. Many linens and silks and various man made fabrics. Calendaring
is also used for polymer materials. Extruded PVC Sheets are produced by this method.

c Direct Extrusion process:-

1 Mark for
Explanation,
01 marks Fig

02 Marks for
advantage
and 02 Marks
for
disadvantage

(Any two)

Direct extrusion process is shown in fig. The raw material used is a billet. It consists of
a press operated ram and a cylinder or container into which the heated billet is placed.
A dummy block is used between the ram and the hot metal. With application of ram
pressure, the metal first plastically fills the cylindrical shape. And it is then forced out
through the die opening until a small amount remains in the container.
Advantages of Direct Extrusion:-
1) close tolerance can be achieved with production of long shells
2) Direct extrusion can be employed for extruding solid circular or non-circular sections,
hollow sections such as tubes or cups
Disadvantages of Direct Extrusion:-

1) Friction between the container and billet is high

2) greater forces are required
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3) the corresponding extrusion pressure is also higher because of friction between
container and billet.
Advantages of Indirect Extrusion:-

1) there is less friction between the container and billet.

2) Less forces are required for indirect extrusion.

3) Indirect extrusion can produce hollow (tubular) cross sections,

Disadvantages of Indirect Extrusion:-

1) Indirect extrusion cannot be used for extruding long extrudes.

2) Support of the ram becomes a problem as work length increases.

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