C 2
Reg No.:
APJ ABDUL KALAM TECHNOLOGIC
Fourth Semester [Link] Degree Supplementary Examina
Course Code: MET204
Course Name: MANUFACTURING PROCESS
Max. Marks: 100 Duration: 3 Hours
PART A
(Answer all questions; each question canies 3 marks) Marks
I What are different shrinkages taking place during the solidification of molten 3
metal from pouring temperature to room temperature? How can they be
compensated?
2 List any three desirable properties of pattern material used in metal casting. 3
3 What are the advantages of Laser Beam Welding over Electron Beam Welding? 3
4 What are the functions of coatings given to electrodes in arc welding? 3
5 What are the ways to reduce the occurrence of chatter during rolling operation? 3
Give any three.
6 what is spreading in rolling operation? what are its causes (any 2)? 3
7 Give any three reasons for die failure in forging operation. 3
I A round billet made of 70-30 brass is extruded at a temperature of 675"C. The 3
billet diameter is 125 mm, and the diameter of the extrusion is 50 mm. Calculate
the extrusion force. Given that for 70-30 brass, extrusion constant is 250 Mpa at
the given extrusion temperature.
9 List any three major processing parameters in shearing. J
l0 What are the basic requirements of clamping devices? 3
I
PARLB
(Answer onefull questionfrom each module, each question carries 14 morks)
Module -l
I I a) With neat sketch, explain the role of various components of gating system in 7
casting.
b) With neat sketches, explain the role of core, core prints and chaplets in metal 7
casting operations.
12 a) with neat sketches, explain an expendabre pattern casting processes. g
b) With neat sketch, explain the different accessories used in gating system of 6
casting?
Page 1 of 2
1i
020mM8T204062203
Module -2
l3 a) With neat sketches, explain the characteristics of different types of flames used in g
gas welding.
b) Compare the characteristic features of Gas Metal Arc Welding and Metal Inert 5
Gas Welding operation.
14 a) Define weldability. Briefly explain any 6 factors influencing weldability of 7
engineering materials.
b) Compare the following characteristics when arc welding is performed using 7
Direct Current straight polarity and Direct Current reverse polarity
i. Heat generation at the base metal
ii. Depth of penetration
iii. Melting point of metals that can be welded
iv. Thickness of metals that can be welded
v. Welding speed
vi. Melting rate of electrode
vii. Heat generation at electrode
Module -3
15 a) With neat sketches, explain shape rolling, roll forging and tube rolling. 9
b) Comparing with metal casting,.what are the advantages of plastically deforming 5
materials to achieve final product.
16 a) With neat sketches, explain any four rolling defects. 8
b) List any three advantages and disadvantages of hot rolling operation. 6
Module 4
l7 a) With neat sketches, compare and contrast direct and indirect extrusion processes. l0
b) What are the factors influencing the selection of die material for forging 4
operations?
l8 a) operations.
With neat sketches explain open die and closed die forging l0
b) What are the factors to be incorporat*l to avoid tearing of sheet metal duing 4
deep drawing operation?
Module -5
19 a) Explain the four basic principles of location. 8
b) With neat diagrams briefly explain what is meant by trimming, shaving, nibbling, 6
and notching.
20 a) With neat diagrams, explain compound die, combination die and progressive die. 9
b) List any five factors to be considered while designing for clamping. 5
Page 2 of 2
C 02000MET204052102
Reg No. : Name:
APJ ABDUL KALAM TECHNOLOGICAL UNIVERSIT
[Link] Degree S4 (R,S) (FTAVP/PT) Exam April 2025 (2019 Scl
Tng=3f=f5==±j
HEEHi-E!
Course Code: MET204
Course Name: MANUFACTURING PROCESS
Max. Marks: 100 Duration: 3 Hours
PART A
(Answer all questions,. each question carries 3 marks)
1 What are the considerations for selecting pattern materials?
2 Distinguish between internal chills and external chills. Which is more effective? 3
3 Oxidizing flame is desirable during welding of copper alloys. Comment. 3
4 Draw a sketch and explain the principle of arc welding. 3
5 Derive an expression for power required per roll in rolling process. 3
6 List any three methods to reduce roll forces in a rolling process. 3
7 Draw a schematic diagram of a coining process and explain. 3
8 Distinguish between hot forging and cold forging. 3
9 State three basic rules of clamping. 3
10 Define and explain limiting drawing ratio in deep drawing process. 3
PART 8
(Answer one full question from each module, each question carries 14 marks)
Module -1
11 a) Write anote on design and positioning of risers.
ti) Sketch any three types of cores. Explain the process of core making.
12 a) With a block diagram, explain production steps in sand casting operation. 8
b) Write a note on i) inspection of castings, and ii) casting defects. 6
Module -2
13 a) Draw a schematic of a shielded metal-arc welding process. Why is it known as 7
stick welding? List any four practical applications of the process.
Page 1 of 2
02000MET204052102
b) Draw the general view and cross-sectional view of a torch used in oxyacetylene 7
welding.
14 a) Draw a neat sketch ofa resistance spot welding process. Write a note on process 7
capability of spot welding.
b) What are the methods for testing defects in welds? Prepare a chart showing any 7
three defects in welding and the corresponding method of testing of defects.
Module -3
15 a) Draw a neat sketch and explain the hot rolling process. Distinguish between hot 7
rolling and cold rolling.
b) Define thread rolling. With the help of schematics, explain the steps in thread 7
rolling process. Give any two applications of thread rolling.
16 a) Write a note on i) heat generation and ii) heat transfer in metal forming. 7
b) Draw a neat sketch and explain the metal flow pattern in bulk deformation of 7
metals. Discuss how to calculate force and power in a typical bulk deformation
process.
Module -4
17 a) Differentiate between hubbing, incremental forging and isothermal forging. 7
Represent using neat sketches.
b) Draw neat schematics and explain any two extrusion defects.
18 a) Define wire drawing. Derive an expression for drawing force, assuming 6
frictionless conditions.
b) Draw a neat sketch and explain rotary-swaging process. Write a note on swaging 8
of tubes.
Module -5
19 a) Explain the basic principle of location using a neat sketch. 7
b) Distinguish between hydraulic clamping and pneumatic clamping. 7
20 a) Draw neat sketches of any three stretch forming operations. 6
b) Draw sketches and explain i) compound die, ii) progressive die. 8
***
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c 02000MET204062205
Reg No.:
.>. Ir
APJ ABDUL KALAM TECHNOLOGICAL UNIVE
[Link] Degree 54 (R,S) / 54 (PT) tn,'Sl I 54 (WP) (R) Examination May
Course Code: MET204
Course Name: MANUFACTURING PROCESS
Max. Marks: 100 Duration:3 Hours
PART A
(Answer oll questionsl each question carries 3 marks) Marks
I List the advantages of casting process over shaping process? J
2 Explain the functions of riser? J
3 Discuss the difference between brazing and soldering? 3
4 Explain the principle of TIG welding? 3
5 Define rolling. Differentiate hot rolling from cold rolling?
a
J
6 With the aid of a sketch, explain thread rolling. J
7 Describe briefly the extrusion defects? J
8 Distinguish between open and closed die forging processes?
a
J
9 Explain the principles of clamping? J
l0 Differentiate between wire drawing and bar drawing? 3
PART B
(Answer onefull questionfrom each module, each question carries 11 marks)
Module -1
l.l a) With the help of a neat sketch, explain the principle of gating system? 7
.b) Explain Lost wax process? ,7
12 a) Explain the various properties of moulding fihaZ 6
b) Explain the various casting defects? 8
Module -2
13 a) Explain submerged arc welding process with the help of a neat sketch? 7
b) Explain the oxy-acetylene welding process. Also explain its various flame 7
characteristics?
14 a) Explain any one resistance welding process? 5
b) Discuss the factors that influence weld quality? 5
c) Explain straight and reversed polarities in arc welding? 4
'Page 1 of 2
02(n0MET20,4062205
Module -3
l5 a) Explain how I beams and axle.s are made by rolling? 7
b) Explain the various defects observed in rolled plates? 7
l6 a) An annealed copper strip 300 mm wide and 30 mm thick is rolled to thickness 25 5
mm in one pass. The roll radius is 350 mm and rolls rotate at 120 rpm. Calculate
the roll force and power required in this operation?
Assume average flow stress of copper as 180 MPa
b) ClassiS the types of rolling mills and sketch them.
Module -4
t7 a) Explain the various defects in forged parts. 6
b) Define deep drawing processes and explain its features and applications. 8
l8 a) With the help of a sketch, explain impression die forging? 7
b) Explain hydrostatic extrusion and impact extrusion using neat sketches? 7
Module -5
t9 a) Explain the various sheet metal forming operations? 9
b) Differentiate between Vacuum clamping and magnetic clamping? 5
20 a) With the aid of the sketch, explain stretch forming? 5
b) Explain the features and working of inverted dies, compound dies and 9
progressive dies.
***
Page 2 of 2
c 02000MET204062202
Reg No.:
t
APJ ABDUL KALAM TECHNOLOGICAL UN
[Link] Degree 54 (S, FE) / 54 (PT) (S) Examination January 2024 (201
Course Code: MET204
Course Name: MANUFACTURTNG PROCESS
Max. Marks: 100 Duration: 3 Hours
PART A
(Answer all questions; each question caties 3 marks) Marks
I What is Caine's method? What is its importance? a
J
2 The runner is tapered from its top to bottom. Why? a
J
3 What is the relation between the grain size and hardness of a weldment? a
J
4 What are the various types of flames formed in an oxy-acetylene welding 3
process? What are its uses?
5 What is forward slip and backward slip in a rolling process? What is its 3
importance in rolling process?
6 Differentiate between hot rolling and cold rolling processes. J
7 What is flash in forging process? What is its importance? 5
8 List any three defects that can occur in an extrusion process. J
9 Enlist the various locating methods used to fix a work piece. 3
l0 What is cavity location? How is it accomplished? J
PART B
(Answer onefull question from eoch module, each question carries 14 marks)
Module -1
I I a) List the various types of allowances which are usually provided in a pattern. 7
Explain any four. .;
b) process.
with the help of a neat sketch, explain the hot chamber die casting 7
12 a) Explainlhe vacuum arc remelting process. What are its applications? 7
b) With the help of neat sketches, explain the various defects that can occur in a cast 7
part.
Module -2
l3 a) Describe the common types of discontinuities in welded joints. 8
b) How does the percussion welding process carry out? What are its advantages and 6
disadvantages?
'
Page 1 of 2
02000MET204062202
t4 a) with a neat sketch, explain the shielded metal arc werding process. 7
,!,
b) Explain the electron beam wlHing process with the help of a neat diagram. 7
Module -3
t5 a) With the help of neat sketches, explain the mechanics of the flat rolling process. 7
b) Explain the various steps involved in finding out the roll forces [Link] hot rolling 7
process.
t6 a) Give an account of various types of rolling defects. 8
b) With a neat sketch, explain the thread rolling process. 6
Module 4
17 a)' With the help of neat sketches, explain the various steps involved in the closed
die forging process.
.f
b) Analyse the forging process using the slab method. 7
18 a) With the help of neat diagrams, explain the wire drawing process. 7
b) Explain the various types of impact extrusion process and its uses. 7
Module -5
19 a) With the help of neat sketches, explain the locating from plane, circular and
irregular surface.
b) Explain the various steps in nibbing and notching operation with neat sketches. 7
20 a) With the help of neat diagrams, explain the inverted, compound and progressive 7
dies.
b) How embossing process is carried out? what are its apprications?
t rtt
Page2of 2
02000MET20406220r
Name:
APJ ABDUI, [Link] TECHNOLOGICAL UNIVERSITY
[Link] Degree 54 (R,S) / 54 (PT) (R,S) Examination June 2023 (2019
Course Code: MET204
Course Name: MANUFACTURING PROCESS
Max. Marks: 100 Hours
PART A
(Answer all questions; each question caruies 3 marks) Marks
I What is choke area? What is its importance? 3
2 Why?
The size of a pattern is greater than that of a casting. 3
J What is meant by weldability? What is its importance? 3
4 Write down the chemical reactions involved in a thermit weldingprocess. 3
5 What is neutral point? What is its importance in rolling process? 3
6 Explain working of planetary rolling mill with sketch. 3
7 What is meant by forging under sticking condition? 3
8 Draw the cross section of a wire drawing die and mark entry, approach and 3
bearing surface in it.
9 What are the various degrees of freedom enjoyed by an object in space? 3
l0 Differentiate between pin and button locators. 3
PART B
(Answer onefull question from each module, each question carries 14 nrcrks)
Module -l
ll a) Explain the various steps of the sand-casting process with suitable diagrams. 7
b) With the help of a neat sketch explain thercold chamber die casting process. 7
12 a) Explain the squeeze casting process. What are its applications? 7
b) With the help of a neat sketch explain the investment casting process. 7
Module -2
l3 a) Explain the various types of flames formed in an oxy-acetylene welding process. 7
b) How does the resistance welding process carry out? What are its advantages and 7
disadvantages?
14 a) With a neat sketch explain the electro-slag welding process. 7
b) Explain the submerged arc welding process with the help of a neat diagram . 7
Page I of 2
02000MET20&62201
Module -3
l5 a) Explain the various stepst involved in finding out the power requirement
in a 7
rolling process.
b) With a neat sketch, explain the ring rolling process.
7
16 a) Sketch and explain plane stress diagrams for maximum-shear-stress
and 7
d istortion-energy criteria.
b) Give an account of heat generation and heat transfer in metal
forming process.
Module -4
17 a) With the help of neat sketches, explain the various steps involved in
the coining
process.
b) with the help of neat sketches. explain open die and impression die forging
process.
18 a) with the help of neat diagrams. explain the direct and indirect extrusion
processes.
b) Explain the various steps involved in the tube drawing process.
Module -5
19 a) with the help of neat sketches, explain the hydraulic and pneumatic clamping
systems.
b) Explain the various steps in shearing operation with neat sketches.
7
20 a) with the help of neat diagrams, explain the various steps involved in deep 7
drawing process.
b) How spinning process is carried out? what are its apprications?
+f!t
Page 2 of 2
C 02000MET204052103
RegNo.: Name:
APJ ABDUL KAI,AM TECHNOLOGICAL
Fourth Semester [Link] Degree Examination June 2022 ( ji
Course Code: MET204
Course Name: MANUFACTURING PROCESS
Max. Marks: 100 Duration:3 Hours
PART A
(Answer all questions; each question carries 3 marks) Marks
I How do patterns differ from casting? (3)
2 What is the role of core and chill in casting process? (3)
a
J Explain any two destructive tests performed on welded joints. (3)
4 What is shielded metal arc welding? (3)
5 What is thread rolling? Compare it with thread cuffing. (3)
6 Sketch a typical rolling process and define (a) neutral point; (b) lagging and (3)
leading zones; (c) forward and backward slip.
7 What is open die forging? (3)
8 Differentiate between direct extrusion and indirect extrusion. (3)
9 What is sffetch forming? (3)
l0 Describe any three sheet metal operations. (3)
PART B
,Ont_nn onefull questionfrom each module, each question carries 14 marks)
n a) what are,n" *"0, inuotu"o ,' " r":"1#;;process? (7)
b) Sketch and explain the components of agding system in casting process. ' (7)
12 a) Explain the salient features of investment casting process. (7)
b) Two solids of the same material, one a cube and the other a sphere, are cast. (7)
Volume of the cube of side 'a' and that of the sphere of radius 'r' are equal. Find
the ratio of the solidification time of the cube to that of the sphere.
Module -2
13 a) Sketch and explain the basic regions in a typical fusion welded joint. (8)
b) How is welding performed in a thermit welding process? (6)
Page 1 of 2
02000M8T2040s2103
14 a) What are the components in oxy-acetylene welding operation? How is the flame (8)
adjusted in gas welding?
t '
b) Resistance flash welding using 30 V power supply is done to join two pipes each (6)
having inner diameter 100 mm and outer diameter ll0 mm. At the interface, I
-mm
of material melts from each pipe which has a resistan ce of 42.4 O. If the unit
melt energy is 64.4 MJ/m3, find the time required for welding.
Module -3
15 a) Narrate the features of (i) four high rolling mill (ii) planetary rolling mill (iii) (6)
cluster rolling mill.
b) If p is the coefficient of friction between metal and roll surface and R is the (S)
radius of the roll, obtain an expression for maximum possible reduction in a
single pass.
16 a) Define (i) true stress; (ii) flow stress; (iii) average flow stress (6)
b) what is yield criterion? Explain Tresca and von Mises yibld criteria. (8)
Module -4
17 a) Differentiate between hot working and cold working of metals. compare the (6)
relative merits and demerits of hot working and cold working.
b) Disinguish between drop forging and press forging. (S)
18 a) Differentiate between wire drawing and deep drawing. (6)
b) Applying the slab method, obtain an expression for forging pressure under plane (S)
strain conditions with sliding friction.
Module -5
19 a) What is 3-2-Lprinciple? (6)
b) List the different locating methods and explain any two of them. (8)
* 20 a) Explain spring back which is observed in
eheet metal bending. , (6)
b) What are the main principles ofclamping? Give a classification of clamps used. (8)
***
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c
ffi"u=Gg)
:J-_./**b11
02000MET204052101
Reg No.: Name:
APJ ABDUL KALAM TECHNOLOGICAL
Fourth Semester [Link] Degree ExaminationJuly 202
Course Code: MET204
Course Name: MANUFACTURING PROCESS
Max. Marks: 100 Duration: 3 Hours
PART A
\ (Answer all questions; each question carries 3 marks) Marks
List any three causes of occurrence of shrinkage in castings. 3
Differentiate between composite moulds, permanent moulds and expendable 3
moulds.
I
J Write down any three practical applications of thermit welding. J
a
4 What are the causes of porosity in welds? How can it be controlled? J
a
) Define (a) neutral point and (b) draft in a flat rolling process. J
a
6 Represent alligatoring in rolled sheets with a neat sketch and explain. a
J
7 Draw and explain any three defects in forged parts. J
8 Distinguish bef-ween drawing and extrusion processes. a
J
9 List any three press tool operations. a
J
l0 Draw a neat sketch to represent shear action in die cutting operation. a
J
PART B
(Answer onefull questionfrom each module, each question carries 14 marks)
Module -1
ll a) write a note on selection of patterns for castings. Sketch any two types of
patterns.
b) Explain i) permeability, ii) cohesiveness and iii) refractoriness of moulding
sand. s
12 a) Represent the temperature-time graph of i) pure metal, and ii) alloy. Draw the g
heat extraction pattern in i) sand mould and ii) metal mould.
b) What are the requirements of an ideal gating system? 6
Module -2
13 a) Draw a neat sketch of friction welding and explain the mechanisms of welding. 6
Page 1 of 2
02000M8T204052101
, b). Define weldability. Explain the weldability characteristics of i) stainless steels, 8
,
ii) copper alloys and iii) tungsten.
14 a) Draw a schematic of various regions in a fusion weld zone. Write a note on 6
HAZ.
b) Explain any four destructive tests for testing welded joints. 8
Module -3
15 a) Draw and explain any four roll arrangements in a rolling mill. 8
''b) rolling.
Write a note on residual stresses developed in 6
16 a) Define hot working. List any four advantages of hot working. 6
(' b) Explain Von Mises' maximum distortion energy criterion in plastic flow. Draw 8
.if a neat sketch and give an example.
Module -4
17 a) Define and explain forging process. Explain the method of choosing forging 8
temperature range for metals.
b) Draw the sketches of any three extrusion-die configurations. 6
18 a) Draw a neat sketch of a die used for wire drawing. Write a short note on die 8
materials.
b) Distinguish between wet drawing and dry drawing. Write a note on roll 6
straightening of a drawn round rod.
Module -5
.r 19 a) Draw a neat sketch and explain: i) conical locators, ii) adjustable locators and 6
iii) profile locators.
b) Draw and explain: i) location of bar in vee block, ii) location in two vees, 8
iii) location of a rectangular job and iv) location of a job for drilled holes.
20 a) Draw the sketch of a die assembly for press working and explain all the 6
components.
b) Draw neat sketches of the following sheet metal bending operations: 8
i) hemming, ii) flanging, iii) beading and iv) roll forming.
'F**
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