a) Zeroth Law of Thermodynamics & importance Manufacturing processes are selected based on shape complexity, material proper es,

lected based on shape complexity, material proper es, cost, and

If two systems are each in thermal equilibrium with a third system, then they are in thermal produc on volume. Cas ng, welding, and forming are widely used processes with different
equilibrium with each other. characteris cs.
Importance: It forms the basis for measurement of temperature and use of thermometers. 1) Cas ng
b) Entropy & its unit Cas ng is a manufacturing process in which molten metal is poured into a mould and allowed to
Entropy is a thermodynamic property that represents the degree of disorder or randomness of a solidify into the desired shape.
system. Features:
Unit: Joule per Kelvin (J/K).  Suitable for complex and intricate shapes
c) Significance of cri cal point of a substance  Can produce very large components
The cri cal point is the state at which liquid and vapor phases become indis nguishable. Beyond  Allows use of metals with poor machinability
this point, a gas cannot be liquefied by pressure alone. Advantages:
d) Difference between SI and CI engines  Complex shapes can be produced easily
SI Engine CI Engine  Internal cavi es are possible
Uses spark plug No spark plug  Low material wastage
Uses petrol Uses diesel Limita ons:
Low compression ra o High compression ra o  Poor surface finish
Fuel-air mixture ignited by spark Fuel ignites due to high temperature  Defects like shrinkage and porosity
 Mechanical proper es are rela vely lower

e) Specific gravity of a fluid Applica ons: Engine blocks, pipes, pump housings
Specific gravity is the ra o of the density of a fluid to the density of water at 4°C. 2) Welding
It is dimensionless. Welding is a joining process in which two or more metal parts are permanently joined by fusion or
f) Difference in pressure between 10 m mercury column and 10 m water column pressure, with or without filler material.
Δ𝑃 = (𝜌 − 𝜌 )𝑔ℎ Features:
= (13600 − 1000) × 9.81 × 10  Produces strong permanent joints

= 1.236 × 10 Pa (approx)  Used for repair and fabrica on

g) Criteria for selec on of manometric fluid  Applicable to similar or dissimilar metals
 High density Advantages:
 Low vapor pressure  High joint efficiency
 Immiscible with the measured fluid  Light-weight structures
 Clear and visible meniscus  No need for holes or fasteners
 Should not s ck to the tube walls Limita ons:
h) Hardness & hardest/so est engineering material  Residual stresses and distor on
Hardness: Resistance of a material to indenta on or scratching.  Requires skilled labor
 Hardest: Diamond  Inspec on is difficult
 So est: Lead Applica ons: Bridges, shipbuilding, pressure vessels
i) Two advantages of belt drives 3) Forming
1. Simple and inexpensive Forming is a process where plas c deforma on is used to change the shape of a metal without
2. Absorbs shock and vibra on removing material.
j) Degree of Freedom (DOF) of a robot Features:
DOF is the number of independent movements or mo ons a robot can perform.  Material is shaped by compressive forces
 Improves mechanical proper es
Q5 (a) Compare Cas ng, Welding, and Forming Processes  High produc on rate
Advantages:
 High strength due to grain refinement
 Good surface finish
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 Economical for mass produc on Operate using mechanical linkages.

Limita ons: Examples: Band brake, block brake
 High tooling cost Applica ons: Hoists, bicycles
 Limited to duc le materials 2) Hydraulic Brakes
 Complex shapes are difficult Use fluid pressure to apply braking force.
Applica ons: Rolling sheets, forging sha s, extrusion of rods Advantages: Smooth and uniform braking
Comparison Table Applica ons: Cars, buses, motorcycles
Aspect Cas ng Welding Forming 3) Pneuma c Brakes
Purpose Shape making Joining Shape change Operate using compressed air.
Material state Molten Solid Solid Advantages: High braking force
Waste Moderate Minimal Nil Applica ons: Trucks, trains
Strength Low High Very high 4) Disc Brakes
Shape complexity Very high Limited Moderate Use calipers to press pads against a rota ng disc.
Advantages: Be er heat dissipa on
Q5 (b) Role of Material Proper es in Manufacturing Process Selec on Applica ons: Cars, sports bikes
Material proper es play a crucial role in selec ng an appropriate manufacturing process because 5) Drum Brakes
they determine how a material behaves under heat, force, and deforma on. Brake shoes press against the inside of a drum.
1) Mechanical Proper es Advantages: Simple construc on
 Duc lity: Required for forming processes like rolling and extrusion Applica ons: Rear wheels of vehicles
 Strength: High-strength materials need powerful machines 6) Electromagne c Brakes
 Hardness: Hard materials are difficult to machine Use magne c fields to produce braking force.
2) Thermal Proper es Advantages: No physical contact
 Mel ng point: Low mel ng point materials are suitable for cas ng Applica ons: Elevators, electric trains
 Thermal conduc vity: Affects welding and solidifica on
 Thermal expansion: Influences distor on during welding Q6 (b) Anatomy of a Robot with Block Diagram
3) Chemical Proper es A robot is an electromechanical system capable of performing tasks automa cally with the help of
 Oxida on resistance: Important in high-temperature processes sensors and control systems.
 Corrosion resistance: Determines surface treatment needs Main Components of a Robot
4) Physical Proper es 1. Controller – Brain of the robot that processes commands
 Density: Influences cas ng and forming pressure 2. Sensors – Detect posi on, force, temperature, etc.
 Electrical conduc vity: Important in resistance welding 3. Actuators – Convert energy into mo on
5) Metallurgical Proper es 4. Manipulator (Arm) – Performs work
 Grain structure: Fine grains improve strength 5. End Effector – Tool a ached to the robot (gripper, welder)
 Phase transforma on: Affects heat treatment and welding 6. Power Supply – Electrical or hydraulic power source
Conclusion Block Diagram of a Robot
Proper selec on of manufacturing process ensures: Program / Input
 Be er product quality ↓
 Lower produc on cost Controller
 Improved mechanical proper es ↓
 Longer service life Actuators
Q6 (a) Types of Brakes and Their Applica ons ↓
Brakes are mechanical devices used to slow down or stop mo on by conver ng kine c energy into Manipulator (Arm)
heat. ↓
1) Mechanical Brakes End Effector
↑
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 Sensors Process Change of state
Working Path Route of process
 Controller receives input commands Cycle Closed sequence of processes
 Sensors provide feedback
 Actuators move the manipulator Q2 (b) Limita ons of the First Law of Thermodynamics and How They Are Addressed
 End effector performs the task The First Law of Thermodynamics is a statement of energy conserva on.
First Law Statement
Q2 (a) Explain the terms: Process, Path, State, and Cycle in Thermodynamics with Illustra ve Energy can neither be created nor destroyed, only converted from one form to another.
Diagrams
Thermodynamics deals with energy interac ons in systems. Certain basic terms are used to Limita ons of the First Law
describe system behavior. 1. No Direc on of Heat Flow
1) Thermodynamic System It does not specify the direc on in which heat flows naturally.
A system is a specified quan ty of ma er or a region in space chosen for study. 2. No Criterion for Process Feasibility
2) State Cannot predict whether a process is possible or not.
The state of a system is the condi on of the system defined by its thermodynamic proper es such 3. Does Not Account for Irreversibility
as pressure, temperature, and volume. It does not dis nguish between reversible and irreversible processes.
 If all proper es are known, the state is completely specified. 4. No Limit on Heat-to-Work Conversion
 Represented by a point on a property diagram. It does not restrict conversion of heat completely into work.
Example: 5. Does Not Define Engine Efficiency
Gas at 2 bar pressure and 300 K temperature. Cannot determine maximum possible efficiency of heat engines.
State A (P1, V1) How These Limita ons Are Addressed
3) Process These shortcomings are resolved by the Second Law of Thermodynamics, which:
A process is the transforma on of a system from one state to another.  Defines direc on of heat flow
 Occurs due to interac on with surroundings  Introduces entropy
 May involve heat and work transfer  Sets limits on efficiency
Example: Expansion or compression of gas.  Explains irreversibility
A ───────► B The First Law is essen al but incomplete without the Second Law.
(Process)
4) Path Q2 (c) Second Law of Thermodynamics with Kelvin–Planck and Clausius Statements
The path is the actual route followed by a system during a process. The Second Law introduces the direc on and limita ons of energy conversion.
 Different paths between the same states give different heat and work values. Kelvin–Planck Statement
 Hence, heat and work are path func ons. It is impossible to construct a heat engine that operates in a cycle and converts all the heat
A ──Path 1──► B absorbed from a single reservoir completely into work.
A ──Path 2──► B Implica on:
 100% efficient heat engine is impossible.
5) Cycle  Some heat must be rejected.
A cycle is a series of processes a er which the system returns to its ini al state. Clausius Statement
 Net change in internal energy in a cycle is zero. It is impossible for heat to flow from a colder body to a ho er body without external work.
Example: Heat engine cycle. Implica on:
A ─► B ─► C ─► A  Explains working of refrigerators and heat pumps.
 Heat flows naturally from hot to cold.
Conclusion Equivalence of Statements
Term Defini on  Viola on of Kelvin–Planck implies viola on of Clausius and vice versa.
State Condi on of system  Both express the same physical principle.

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Conclusion  Diameter of ram, 𝐷 = 15cm

The Second Law:  Diameter of plunger, 𝐷 = 1.5cm
 Defines direc on of heat flow  Load on ram, 𝑊 = 25kN = 25,000 N
 Introduces entropy Principle Used
 Governs all real thermodynamic processes Hydraulic press works on Pascal’s Law, which states that pressure applied to a confined fluid is
Q2 (d) Explain the Modes of Heat Transfer with Suitable Examples transmi ed equally in all direc ons.
Heat transfer is the movement of thermal energy from a region of higher temperature to a region 𝐹 𝐹
=
of lower temperature. There are three modes of heat transfer. 𝐴 𝐴
1) Conduc on Calcula on
Conduc on is the mode of heat transfer in which heat flows through a material without any 𝐹 25000
=
physical movement of the material par cles. 𝜋(1.5/2) 𝜋(15/2)
 Occurs mainly in solids 𝐹 25000
=
 Heat is transferred due to molecular vibra on and free electrons 1.5 15
Example: 1.5
𝐹 = 25000 ×
 Hea ng one end of a metal rod causes the other end to become hot 15
1
 Heat transfer through walls of a furnace 𝐹 = 25000 ×
Key Point: 100
𝐹 = 250 N
Conduc on depends on thermal conduc vity of the material.
2) Convec on
Convec on is the mode of heat transfer in which heat is transferred by actual movement of fluid
Answer
par cles.
The force required on the plunger is 250 N.
It occurs only in liquids and gases.
Q2 (f) Define Viscosity. Causes of Viscosity and Effect of Temperature
Types of Convec on:
Defini on of Viscosity
 Natural (Free) Convec on: Due to density difference caused by temperature varia on
Viscosity is the property of a fluid that resists the rela ve mo on between adjacent layers of the
 Forced Convec on: Fluid mo on caused by external devices like pumps or fans
fluid.
Examples:
 It represents internal resistance to flow.
 Circula on of water during boiling
 Unit: Pa·s (N·s/m²)
 Cooling of automobile engines using fans
Causes of Viscosity
3) Radia on
1) In Liquids
Radia on is the mode of heat transfer in which heat is transferred in the form of electromagne c
 Caused by cohesive forces between molecules
waves, without the need of any medium.
 Stronger molecular a rac on → higher viscosity
 Can occur in vacuum
2) In Gases
 Depends on surface temperature and emissivity
 Caused by momentum exchange between fast-moving molecules
Examples:
 Molecular collisions create resistance to flow
 Heat from the sun reaching the earth
Varia on of Viscosity with Temperature
 Heat felt near a fire or electric heater
For Liquids
Comparison Summary
 Viscosity decreases with increase in temperature
Mode Medium Required Example
 Because molecular bonds weaken
Conduc on Yes Metal rod
Example: Engine oil flows easily when heated
Convec on Yes (fluid) Boiling water
For Gases
Radia on No Solar heat
 Viscosity increases with increase in temperature
 Due to increased molecular mo on
Q2 (e) Hydraulic Press Problem Example: Air resistance increases at high temperature
Given: Conclusion
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 Fluid Effect of Temperature  Control moisture content
Liquid Viscosity decreases  Use dry moulds
Gas Viscosity increases 2) Shrinkage Cavity
Descrip on: Voids formed due to metal shrinkage during solidifica on
Q2 (g) Define Vapour Pressure of a Liquid. Rela on with Boiling and Parameters Affec ng Vapour Causes:
Pressure  Insufficient feeding
Defini on of Vapour Pressure  Improper riser design
Vapour pressure is the pressure exerted by the vapour of a liquid when it is in dynamic Remedies:
equilibrium with its liquid at a given temperature.  Proper riser placement
 At equilibrium, the rate of evapora on equals the rate of condensa on.  Use chills
 Vapour pressure is a func on of temperature only. 3) Cold Shut
Rela on between Vapour Pressure and Boiling Descrip on: Incomplete fusion of molten metal streams
A liquid is said to boil when its vapour pressure becomes equal to the surrounding (atmospheric) Causes:
pressure.  Low pouring temperature
 At sea level, boiling occurs when vapour pressure = 1 atm.  Slow pouring rate
 At high al tudes, atmospheric pressure is lower → boiling occurs at lower temperature. Remedies:
 In pressure cookers, higher pressure increases boiling temperature.  Increase pouring temperature
Parameters Affec ng Vapour Pressure  Improve ga ng design
1) Temperature 4) Misrun
 Vapour pressure increases with increase in temperature Descrip on: Incomplete filling of mould cavity
 More molecules escape from liquid surface Causes:
2) Nature of Liquid  Low fluidity of metal
 Liquids with weaker intermolecular forces have higher vapour pressure  Thin sec ons
 Vola le liquids (e.g., petrol) have high vapour pressure Remedies:
3) Intermolecular Forces  Increase metal temperature
 Stronger molecular a rac on → lower vapour pressure  Modify cas ng design
 Hydrogen bonding reduces vapour pressure 5) Hot Tears (Cracks)
Descrip on: Cracks formed during solidifica on
4) Purity of Liquid Causes:
 Presence of impuri es generally reduces vapour pressure  Restrained contrac on
 Dissolved solids lower evapora on rate  Poor mould collapsibility
Vapour pressure governs boiling and evapora on and plays a crucial role in phase change Remedies:
processes.  Improve mould collapsibility
Q2 (h) Common Cas ng Defects, Their Causes, and Remedies  Proper cas ng design
Cas ng defects occur due to improper mould design, material proper es, or faulty process 6) Sand Inclusion
parameters. Descrip on: Sand par cles trapped in cas ng
1) Blow Holes Causes:
Descrip on: Smooth, round cavi es inside the cas ng  Weak mould
Causes:  High metal velocity
 Excess moisture in mould Remedies:
 Poor ven ng  Improve mould strength
 Gas entrapment  Reduce pouring velocity
Remedies: Conclusion
 Proper ven ng Proper control of mould proper es, pouring condi ons, and cas ng design can minimize cas ng
defects and improve quality.
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