MANUFACTURING PROCESS

A) What is meant by Manufacturing Processes? How will you select

any suitable manufacturing process for the products?
Manufacturing Processes refer to the steps through which raw materials
are transformed into a final product. These processes can include casting,
forming, machining, joining, and additive manufacturing.
Selecting a Suitable Manufacturing Process:
● Material Type: The material's properties (e.g., metal, plastic) will
influence the choice of process.
● Design Complexity: Complex designs may require more advanced
processes like CNC machining or 3D printing.
● Production Volume: High-volume production may benefit from
processes like injection molding or stamping.
● Cost: Budget constraints can limit the choice of processes.
● Tolerances and Surface Finish: Precision requirements will dictate the
process.
● Lead Time: The time available for production can affect the choice.
B) What is the requirement of shrinkage allowances? Explain the
defects in the casting processes.
Shrinkage Allowances: Shrinkage allowances are necessary to
compensate for the reduction in volume that occurs when a metal solidifies
and cools. This ensures that the final casting dimensions are accurate.
Defects in Casting Processes:
● Porosity: Small holes or voids within the casting.
● Shrinkage Defects: Cavities or depressions due to improper
shrinkage allowance.
● Cold Shuts: Incomplete fusion of two streams of molten metal.
● Hot Tears: Cracks formed due to internal stresses during cooling.
● Misruns: Incomplete filling of the mold.
C) Describe any suitable metal casting process for manufacturing the
pump casing.
Sand Casting:
● Pattern Making: Create a pattern of the pump casing.
● Mold Making: Form a sand mold around the pattern.
 ● Melting: Melt the metal to be cast.
● Pouring: Pour the molten metal into the mold.
● Cooling: Allow the metal to cool and solidify.
● Shakeout: Break the mold to retrieve the casting.
● Finishing: Clean and finish the casting to the desired specifications.
A) How will you roll any sheet material? Explain one rolling process in
detail.
Rolling Process:
● Preparation: Clean and prepare the sheet material.
● Heating (if necessary): Heat the material to the required temperature.
● Rolling: Pass the material through rollers to reduce thickness and
achieve the desired shape.
Detailed Process - Hot Rolling:
● Heating: Heat the metal above its recrystallization temperature.
● Rolling: Pass the heated metal through a series of rollers
● Cooling: Cool the rolled metal gradually.
● Finishing: Trim and finish the rolled product.
B) Differentiate between open die and closed die forging with its
suitability and applications.

C)What do you understand by extrusion and drawing processes?

Explain one of the both in detail.
Extrusion: Extrusion is a manufacturing process where a billet (a solid
block of material) is forced through a die to create a long shape with a
constant cross-section. The process can be performed with metals,
polymers, ceramics, and food products
Types: There are two main types of extrusion: hot extrusion (performed at
elevated temperatures) and cold extrusion (performed at or near room
temperature).
Drawing: Drawing is a process where a metal rod, wire, or tube is pulled
through a die to reduce its diameter and increase its length. This process is
typically used for producing wires, rods, and tubes with precise dimensions
and smooth surfaces.
Types: There are two main types of drawing: wire drawing (for wires) and
tube drawing (for tubes).
Detailed Explanation of Extrusion Process:
Hot Extrusion: • For metals having low ductility at room temperature or in
order to reduce forces required for extrusion, the extrusion is carried out at
elevated temperature. For lead 200 to 250°C, aluminium 375 to 475°C,
copper 650 to 975°C, steels 875 - 1300°C and refractory alloys 975 to
2200°C are temperatures of extrusion for some metals.
• Die wear can be excessive. Cooling of hot billet in cold container may
cause problems and affect flow of metal in the die, producing non-uniform
deformation. Extrusion dies may be heated to avoid this. Hot billet
develops undesirable oxide films. To avoid this, dummy block (pressure
plate) placed ahead of ram is made a little smaller in diameter than
container. Thus after extrusion, a thin cylindrical shell is left in container
which is later removed. Special considerations are given for die designing
of dies for hot extrusion. Lubrication is important in hot extrusion. Glass is
used for steels, stainless steel and high temperature metals and alloys.
Cold extrusion:This term denotes a combination of operations such as
direct and indirect extrusion and forging. This is used for making tools and
parts of automobiles, farm equipments. Starting material is slug cut from
cold finished or hot rolled bar, wire or plate. Cold extrusion has following
advantages: • Improved mechanical properties because of work
hardening. • Good control of tolerance. No subsequent machining is
required. • Improved surface finish. • No billet heating. • High production
rate. Disadvantages are magnitude of stresses on tooling in cold extrusion
is very high. Lubrication is critical.
D) Define formability. Elaborate the sheet metal forming processing
with various characteristics and types of shearing dies?
Formability is the ability of a material, particularly sheet metal, to undergo
plastic deformation without being damaged. It is a critical property in
manufacturing processes where the material is shaped into a desired form
through bending, stretching, or compressing. High formability means the
material can be easily formed into complex shapes without cracking or
losing its structural integrity.
Sheet Metal Forming Processes:
● Bending: Bending involves deforming the sheet metal along a straight
axis to create a desired angle or shape.
​ Characteristics:
​ Requires precise control to achieve accurate angles.
​ Commonly used for creating flanges, channels, and
brackets.
● Deep Drawing: Deep drawing involves pulling a sheet metal blank
into a die cavity to form a hollow shape, such as a cup or a can.
​ Characteristics:
​ Suitable for producing parts with significant depth.
​ Requires high formability to avoid tearing or wrinkling.
● Stretch Forming: Stretch forming involves stretching the sheet metal
over a form block to achieve a desired shape.
​ Characteristics:
​ Used for large, curved surfaces.
​ Requires uniform stretching to avoid thinning or tearing.
● Stamping:Stamping involves pressing the sheet metal into a die to cut
or form shapes.
​ Characteristics:
​ High-speed process suitable for mass production.
​ Used for creating complex shapes with high precision.
● Roll Forming: Roll forming involves passing the sheet metal through a
series of rollers to achieve a continuous profile.
​ Characteristics:
​ Suitable for long parts with constant cross-sections.
 ​ High production rates with consistent quality.
Types of Shearing Dies:
● Simple Die: A simple die performs a single cutting operation in one
stroke.
​ Characteristics:
​ Basic design with one cutting edge.
​ Suitable for straightforward cutting tasks.
● Compound Die: A compound die performs multiple cutting operations
in one stroke.
​ Characteristics:
​ Combines cutting and punching operations.
​ Increases efficiency by reducing the number of steps.
● Progressive Die: A progressive die performs a series of operations at
different stages as the sheet metal moves through the die.
​ Characteristics:
​ Multiple stations within the die perform sequential
operations.
​ Suitable for high-volume production with complex shapes.
● Transfer Die: A transfer die involves moving the workpiece from one
station to another within the die to perform different operations.
​ Characteristics:
​ Allows for complex forming and cutting operations.
​ Suitable for large parts that require multiple steps.
Characteristics of Sheet Metal Forming:
● Ductility: The material's ability to undergo significant plastic
deformation before rupture.
● Yield Strength: The stress at which a material begins to deform
plastically.
● Thickness: The initial thickness of the sheet metal, which affects the
forming process.
● Surface Finish: The quality of the sheet metal surface, which can
impact the final product's appearance and performance.
● Tooling: The design and quality of the dies and tools used in the
forming process, which influence the accuracy and efficiency of the
operation.
A) Arc Welding and Oxy-fuel Gas Welding Processes
Arc Welding:
​ Process: Arc welding uses an electric arc to melt and join metals. The
arc is created between an electrode and the workpiece, generating
intense heat that melts the metal at the joint.
​ Types:
​ Shielded Metal Arc Welding (SMAW): Uses a consumable electrode
coated with flux to lay the weld.
​ Gas Metal Arc Welding (GMAW): Uses a continuous wire electrode
and shielding gas to protect the weld pool.
​ Gas Tungsten Arc Welding (GTAW): Uses a non-consumable
tungsten electrode and shielding gas, often used for precise welding.
​ Applications: Widely used in construction, automotive, shipbuilding,
and pipeline industries for its versatility and strength.
Oxy-fuel Gas Welding:
​ Process: Oxy-fuel gas welding uses a flame produced by burning a
mixture of oxygen and a fuel gas (commonly acetylene) to melt and
join metals.
​ Equipment: Includes an oxygen cylinder, a fuel gas cylinder,
regulators, hoses, and a welding torch.
​ Applications: Suitable for welding, cutting, and brazing. Commonly
used in metal fabrication, repair work, and plumbing.
​ Advantages: Portable, versatile, and can be used for a variety of
metals and thicknesses.
B) Friction Welding and Resistance Welding
Friction Welding:
​ Process: Friction welding generates heat through mechanical friction
between two workpieces in relative motion to each other. The heat
produced softens the material, allowing it to be joined under pressure.
​ Types:
​ Rotary Friction Welding: One workpiece is rotated while the
other is stationary.
 ​ Linear Friction Welding: Both workpieces are moved linearly
relative to each other.
​ Applications: Used for joining dissimilar metals, automotive
components, aerospace parts, and manufacturing tools.
​ Advantages: Produces strong, high-quality joints without the need for
filler materials or shielding gases.
Resistance Welding:
​ Process: Resistance welding uses electrical resistance to generate
heat and join metals. The heat is produced by passing a high current
through the metal pieces to be joined, which are held together under
pressure.
​ Types:
​ Spot Welding: Used for joining overlapping sheets by creating
weld spots.
​ Seam Welding: Produces continuous welds along a seam.
​ Projection Welding: Uses projections on one of the workpieces
to concentrate the welding current.
​ Applications: Commonly used in the automotive industry,
manufacturing of appliances, and metal furniture.
​ Advantages: High-speed process, suitable for automation, and
produces consistent, high-quality welds.
C) Soldering Techniques and Mechanical Fastening
Soldering Techniques:
​ Process: Soldering uses a filler metal (solder) with a low melting point
to join metals. The solder is melted and flows into the joint by
capillary action.
​ Types:
​ Soft Soldering: Uses solder with a melting point below 400°C,
commonly used in electronics and plumbing.
​ Hard Soldering (Brazing): Uses solder with a melting point
above 400°C, suitable for stronger joints.
​ Applications: Widely used in electronics, plumbing, jewelry making,
and metalwork.
​ Advantages: Low-temperature process, minimal thermal distortion,
and suitable for joining delicate components.
Mechanical Fastening:Process:
Mechanical fastening uses mechanical devices such as screws, bolts,
nuts, rivets, and clips to join materials.
​ Types:
​ Threaded Fasteners: Includes screws, bolts, and nuts, which
create a strong, removable joint.
​ Non-threaded Fasteners: Includes rivets and clips, which create
a permanent joint.
​ Applications: Used in construction, automotive assembly, aerospace,
and consumer products.
​ Advantages: Provides strong, reliable joints, easy to assemble and
disassemble, and does not require heat or special equipment.
A) What are the types of lathe machines? Explain the various
operations performed lathe machines with developments, attachment
and accessories.
Types of Lathe Machines:
● Engine Lathe:
​ Description: The most common type of lathe, used for a wide
range of operations.
​ Applications: General-purpose machining, suitable for both
small and large workpieces.
● Turret Lathe:
​ Description: Equipped with a turret that holds multiple tools,
allowing for quick tool changes.
​ Applications: Mass production of identical parts, reducing setup
time.
● CNC Lathe:
​ Description: Computer Numerical Control (CNC) lathes are
automated and controlled by computer programs.
​ Applications: High precision and complex parts, suitable for
mass production.
● Toolroom Lathe:
 ​ Description: Designed for precision work, often used in tool and
die making.
​ Applications: High-precision machining, prototyping, and
custom parts.
● Bench Lathe:
​ Description: A smaller, portable lathe mounted on a workbench.
​ Applications: Small-scale machining, hobbyist projects, and
educational purposes.
● Capstan Lathe:
​ Description: Similar to turret lathes but with a capstan head for
holding multiple tools.
​ Applications: Batch production of small to medium-sized parts.
Operations Performed on Lathe Machines:
● Turning:
​ Description: Removing material from the outer diameter of a
workpiece to create a cylindrical shape.
​ Applications: Producing shafts, rods, and other cylindrical parts.
● Facing:
​ Description: Cutting the end of a workpiece to create a flat
surface.
​ Applications: Preparing the end of a workpiece for further
machining.
● Parting:
​ Description: Cutting off a part of the workpiece.
​ Applications: Separating finished parts from the raw material.
● Drilling:
​ Description: Creating holes in the workpiece using a drill bit.
​ Applications: Preparing holes for screws, bolts, or further
machining.
● Boring:
​ Description: Enlarging an existing hole to achieve greater
accuracy.
​ Applications: Precision hole finishing.
● Threading:
 ​ Description: Cutting threads on the outer or inner surface of a
workpiece.
​ Applications: Producing screws, bolts, and threaded holes.
● Knurling:
​ Description: Creating a textured pattern on the surface of a
workpiece.
​ Applications: Improving grip on handles and knobs.
Developments, Attachments, and Accessories:
● Developments:
​ CNC Technology: Automation and precision control for complex
machining.
​ Advanced Materials: Use of high-strength alloys and
composites for tooling.
● Attachments:
​ Steady Rest: Supports long workpieces during machining.
​ Follow Rest: Moves with the cutting tool to support the
workpiece.
​ Taper Attachment: Allows for machining tapered surfaces.
● Accessories:
​ Chucks: Hold the workpiece securely (e.g., three-jaw, four-jaw
chucks).
​ Tool Post: Holds and positions the cutting tools.
​ Collets: Provide precise holding for small workpieces.
B) What is the need of drill machine and boring machines? Explain
the various types of drilling machines with reaming and tapping
processes
Need for Drill Machines and Boring Machines:
​ Drill Machines: Essential for creating precise holes in various
materials. Used in manufacturing, construction, and repair work.
​ Boring Machines: Used to enlarge and finish pre-existing holes with
high precision. Critical for achieving tight tolerances and smooth
finishes.
Types of Drilling Machines:
● Bench Drilling Machine:
​ Description: Small, portable machine mounted on a workbench.
 ​ Applications: Light-duty drilling tasks, hobbyist projects, and
small workshops.

● Radial Drilling Machine:

​ Description: Features a radial arm that can be moved and
rotated to position the drill head.
​ Applications: Drilling large and heavy workpieces, providing
flexibility in positioning.
● Upright Drilling Machine:
​ Description: A larger, floor-mounted machine with a fixed drill
head.
​ Applications: Medium to heavy-duty drilling tasks in industrial
settings.
● Gang Drilling Machine:
​ Description: Multiple drill heads mounted on a single table.
​ Applications: High-volume production, allowing multiple holes to
be drilled simultaneously.
● Multi-spindle Drilling Machine:
​ Description: Features multiple spindles that can drill several
holes at once.
​ Applications: Mass production of parts with multiple holes.
Reaming and Tapping Processes:
​ Reaming:
​ Description: A finishing process that enlarges and smooths the
surface of a pre-drilled hole.
​ Applications: Achieving precise hole dimensions and smooth
finishes.
​ Tools: Reamers, which are cylindrical cutting tools with multiple
cutting edges.
​ Tapping:
​ Description: Creating internal threads in a pre-drilled hole.
​ Applications: Preparing holes for screws and bolts.
​ Tools: Taps, which are cutting tools with threads that match the
desired internal thread profile.
A) What is the need of milling machines? Comment on the face and
end milling machines with its suitable applications and processes
capabilities

Need for Milling Machines:

Milling machines are essential in the manufacturing industry for various
reasons:
● Versatility: Milling machines can perform a wide range of operations,
including cutting, drilling, shaping, and slotting, making them versatile
for different machining tasks.
● Precision: They offer high precision and accuracy in machining,
allowing for tight tolerances and fine finishes on workpieces.
● Efficiency: Milling machines can remove material quickly and
efficiently, increasing productivity in manufacturing processes.
● Complexity: They can handle complex geometries and contours,
enabling the production of intricate parts and components.
Face Milling Machine:
Description:
​ Face milling machines are used to cut flat surfaces on the workpiece.
​ The cutting tool rotates perpendicular to the workpiece surface,
removing material in a flat plane.
Applications:
​ Face milling is commonly used for producing flat surfaces, such as
the top surface of a workpiece or creating slots and grooves.
​ Suitable for machining large workpieces with flat surfaces, such as
machine beds, frames, and engine blocks.
Process Capabilities:
​ Capable of high material removal rates, making them efficient for
roughing operations.
​ Can achieve high surface finish quality on flat surfaces.
​ Suitable for both manual and CNC operations, offering flexibility in
machining operations.
End Milling Machine:
Description:
 ​ End milling machines are used to cut on the periphery of the
workpiece, creating profiles, slots, and contours.
​ The cutting tool rotates parallel to the workpiece surface, removing
material along the edges.
Applications:
​ End milling is ideal for creating complex shapes, profiles, and
contours on workpieces.
​ Suitable for machining features like pockets, slots, and holes on the
ends of workpieces.
Process Capabilities:
​ Capable of producing precise and intricate shapes and profiles.
​ Suitable for both roughing and finishing operations, offering versatility
in machining tasks.
​ End milling machines can handle a wide range of materials, from
metals to plastics and composites.
B) If you would like to fabricate gears for the gear box of any vehicle,
which suitable manufacturing method will you select? Explain any
two suitable gear manufacturing processes.
1. Hobbing: Hobbing is a common and efficient method for producing
cylindrical gears, including spur gears, helical gears, and worm gears.
It involves the use of a specialized cutting tool called a hob, which
has a series of equally spaced teeth around its circumference. The
hob is rotated at high speed while being fed axially into the
workpiece, which is typically a blank cylindrical gear. As the hob
rotates, it cuts the teeth into the workpiece, gradually forming the
desired gear profile. Hobbing is suitable for both small and large
production runs and offers high precision and productivity. It is often
used for mass production of gears for automotive applications.
2. Gear Shaping: Gear shaping is another versatile method for
producing gears, particularly for gears with internal teeth (such as
internal spur gears) and gears with irregular profiles. In gear shaping,
a cutting tool called a shaper cutter is used to remove material from
the workpiece to form the gear teeth. The workpiece is mounted on a
rotating spindle, while the shaper cutter is reciprocated in a vertical
motion. By synchronizing the movements of the workpiece and the
 cutter, precise gear teeth can be formed. Gear shaping offers
excellent dimensional accuracy and surface finish and is suitable for
producing gears with complex profiles and tight tolerances. It is
commonly used in the production of gears for various automotive and
industrial applications.
C)Sketch the cross section of a sand mould which is ready for
pouring and label the various important parts. Give a brief write-up on
the following casting terms - Sprue, Gate, Runner, Riser.

Sprue: The pouring cup attaches to the sprue, which is the vertical part of
the gating system. The other end of the sprue attaches to the runners.
Runners: The horizontal portion of the gating system that connects the
sprues to the gates.
Gates: The controlled entrances from the runners into the mould cavities.
Riser: An extra void in the mould that fills with molten material to
compensate for shrinkage during solidification.
D) Explain the following properties of a moulding sand.
i) Adhesivness ii) Collapsibility iii) Permeability
i) Adhesiveness: Adhesiveness in molding sand refers to its ability to stick
together and adhere to the pattern during the molding process. This
property helps in maintaining the shape of the mold and preventing it from
breaking apart.
ii) Collapsibility: Collapsibility of molding sand is its ability to collapse or
break down easily when the molten metal is poured into the mold cavity.
This property is important as it allows the metal to flow smoothly into the
mold and fill all the intricate details of the pattern.
iii) Permeability: Permeability in molding sand refers to its ability to allow
gases and steam to escape from the mold cavity during the casting
process. Good permeability is essential to prevent defects like gas porosity
in the final casting by ensuring that gases can easily escape without getting
trapped in the mold.
E) How does a cold rolling differ from hot rolling in terms of the
process and product? Explain what do you understand by the terms
slab and billet?
Cold rolling and hot rolling are two different processes used in
metalworking, particularly in shaping metals like steel. Here's how they
differ:
1. Process:
- Hot rolling: In hot rolling, the metal is heated above its recrystallization
temperature and then passed through rollers to shape it into the desired
form. This process is used to create products with a uniform thickness and
a smooth surface finish.
- Cold rolling: In cold rolling, the metal is rolled at room temperature or
slightly above it. This process is used to produce products with tighter
tolerances, better surface finish, and improved mechanical properties
compared to hot rolling
2. Product:
- Hot rolling: Products from hot rolling tend to have a scaled surface due
to the high temperatures involved. They are generally less precise in terms
of dimensions but are easier to form and shape.
- Cold rolling: Products from cold rolling have a smoother surface finish
and tighter dimensional tolerances. They are often stronger and harder
than hot-rolled products.
Slab and billet are terms used to describe semi-finished metal products:
- Slab: A slab is a semi-finished steel product with a rectangular
cross-section. It is typically produced by continuous casting and is used as
a starting material for further processing into flat products like sheets,
strips, or plates.
- Billet: A billet is a semi-finished steel product with a square or round
cross-section. It is usually produced by casting or hot rolling and is used as
a starting material for further processing into bars, rods, or other shapes
through processes like extrusion or forging.

D) Distinguish between open- and closed- die forging processes.

What do you understand by the term flash in forging.
● Open-die forging:
​ In open-die forging, the metal is placed between flat dies that
do not completely enclose the workpiece.
​ The metal is shaped by repeated hammering or pressing
actions, allowing it to deform and flow according to the desired
shape.
​ This process is suitable for producing large and simple-shaped
parts that require minimal precision.
● Closed-die forging:
​ In closed-die forging, the metal is placed within a shaped die
cavity that completely encloses the workpiece.
​ The metal is compressed within the die cavity to take on the
shape of the cavity, resulting in parts with precise dimensions
and complex shapes.
​ This process is ideal for producing parts with intricate designs
and tight tolerances.
Flash in forging refers to excess material that is forced out of the die cavity
during the forging process. It is a thin layer of metal that flows out of the die
edges under pressure. Flash serves several purposes in forging:
​ It helps to contain the metal within the die cavity, ensuring that the
part is formed accurately.
​ It acts as a seal to prevent metal from escaping the die cavity
prematurely.
​ It provides additional material that can be trimmed off after forging to
achieve the final desired shape and dimensions of the part.
E) A hole of 10 mm x 25 mm is to be cut in a 3 mm thick sheet. The
shear strength of the material is 80 MPa. Estimate the press load
required.
To estimate the press load required to cut a hole in a sheet, we can
calculate the shear force needed to cut through the material. The shear
force can be calculated using the formula:
Shear Force = Shear Strength x Area of Shear
Given:
- Shear Strength = 80 MPa
- Thickness of the sheet = 3 mm
- Dimensions of the hole = 10 mm x 25 mm
First, we need to calculate the area of shear, which is the perimeter of the
hole multiplied by the thickness of the sheet:
Area of Shear = Perimeter of Hole x Thickness of Sheet
Perimeter of Hole = 2 x (10 mm + 25 mm) = 70 mm
Area of Shear = 70 mm x 3 mm = 210 mm²
Now, we can calculate the shear force:
Shear Force = 80 MPa x 210 mm² = 16,800 N = 16.8 kN
Therefore, the estimated press load required to cut the hole in the 3 mm
thick sheet would be approximately 16.8 kN.
F) Explain with sketches the difference between direct and indirect
extrusion. List the variables which affect the extrusion process
performance.

​ Direct extrusion:
​ In direct extrusion, the billet is placed in a container and a ram
is used to push the billet through a die to form the desired
shape.The material flows in the same direction as the ram
movement, resulting in the extruded product emerging on the
same side as the ram.Direct extrusion is a simpler process
compared to indirect extrusion.
 ​ Indirect extrusion:
​ In indirect extrusion, the die is attached to the ram, and the
billet is held stationary while the ram and die move towards
each other.The material flows in the opposite direction of the
ram movement, leading to the extruded product emerging on
the opposite side of the ram.Indirect extrusion allows for more
complex shapes to be extruded and can result in better surface
finish.
Variables that affect the extrusion process performance include:
● Temperature: The temperature of the billet affects its plasticity and
flow characteristics during extrusion.
● Ram speed: The speed at which the ram moves can impact the
extrusion process, affecting factors like extrusion force and product
quality.
● Die design: The shape and dimensions of the die influence the final
shape and dimensions of the extruded product.
● Billet material properties: The material properties of the billet, such as
its composition and grain structure, affect how it deforms during
extrusion.
● Lubrication: Proper lubrication between the billet and the
container/die can reduce friction and improve the extrusion process.
● Extrusion ratio: The ratio of the cross-sectional area of the billet to the
cross-sectional area of the extruded product affects the extrusion
force and product properties.
G)List out any three differences between brazing and soldering. Write
two applications of each of them. Explain the undercut and cracking
defects in welding.
 ● Differences:
○ Temperature: Brazing occurs above 450°C, while soldering
occurs below 450°C.
○ Filler Material: Brazing uses a filler metal with a higher melting
point than soldering.
○ Strength: Brazing joints are stronger than soldering joints.
● Applications:
○ Brazing: Joining of pipes, joining of dissimilar metals.
○ Soldering: Electronics assembly, plumbing.
● Undercut and Cracking Defects:
○ Undercut: A groove melted into the base metal next to the weld,
often caused by incorrect welding parameters.
○ Cracking: Occurs due to high stress, rapid cooling, or
contamination.
H)Describe the submerged arc welding process in respect of working
principle,advantages and limitations.
Submerged Arc Welding (SAW) is a welding process that involves the
formation of an arc between a continuously fed bare wire electrode and the
workpiece. Here's an overview of the working principle, advantages, and
limitations of submerged arc welding:
Working Principle:
● The welding process is carried out under a layer of granular flux,
which shields the arc, prevents spatter, and protects the molten weld
pool from atmospheric contamination.
● The arc is submerged beneath the flux layer, hence the name
"submerged arc welding."
● The filler wire is continuously fed into the arc, melting and forming a
weld bead as it progresses along the joint.
Advantages of Submerged Arc Welding:
● High deposition rates: SAW is known for its high welding speeds and
deposition rates, making it suitable for welding thick materials.
● Deep penetration: The process can achieve deep weld penetration,
resulting in strong and sound welds.
 ● Minimal spatter: The flux layer helps to contain the welding spatter,
resulting in a cleaner work environment and reducing post-weld
cleanup.
● High-quality welds: SAW produces high-quality welds with good
mechanical properties and uniformity.
● Suitable for long continuous welds: It is ideal for welding long seams
in applications like shipbuilding, pressure vessel fabrication, and
structural steel construction.
Limitations of Submerged Arc Welding:
● Limited to flat or horizontal welding positions: SAW is primarily used
for welding in flat or horizontal positions due to the nature of the flux
layer and the molten weld pool.
● Initial setup costs: The equipment required for submerged arc
welding, including the flux handling system, can be costly.
● Limited mobility: SAW is not as versatile or mobile as some other
welding processes, restricting its use in certain applications.
● Flux handling and disposal: Proper handling and disposal of the flux
material used in SAW are necessary, adding to the overall process
complexity.
● Limited to certain material thicknesses: While SAW is excellent for
thick materials, it may not be as suitable for thin materials due to the
high heat input and potential for distortion.
I) List the methods of taper turning on a lathe. In a turning operation, a
cutting speed of 55 m/min has been selected. At what rpm should a 15
mm diameter bar be rotated?
There are several methods for taper turning on a lathe:
● Offset Tailstock Method
● Compound Rest Method
● Taper Turning Attachment Method
● Form Tool Method
To calculate the required RPM for a 15 mm diameter bar with a cutting
speed of 55 m/min, we can use the formula:
Cutting Speed (m/min) = π x Diameter (mm) x RPM / 1000
Given: Cutting Speed = 55 m/min Diameter = 15 mm
Rearranging the formula to solve for RPM:
RPM = Cutting Speed x 1000 / (π x Diameter)
Substitute the values:
RPM = 55 x 1000 / (π x 15) RPM ≈ 1177.95 / 47.1239 RPM ≈ 25
Therefore, the 15 mm diameter bar should be rotated at approximately 25
RPM to achieve a cutting speed of 55 m/min.
J) What are three basic forms of milling process? Differentiate
between the up milling and down milling. Any three differences.
Three Basic Forms of Milling Process
1. Face Milling:
○ The cutting action occurs primarily at the end corners of the
milling cutter.
○ Used for creating a flat surface on the workpiece.
○ The axis of the cutter is perpendicular to the surface being
milled.
2. Plain (or Slab) Milling:
○ The cutting action occurs along the circumference of the cutter.
○ Used for machining flat surfaces parallel to the axis of the
cutter.
○ The axis of the cutter is parallel to the surface being milled.
3. End Milling:
○ The cutter rotates on an axis vertical to the workpiece.
○ Suitable for cutting profiles, slots, and pockets.
○ Can be used for both horizontal and vertical milling operations.
Differences Between Up Milling and Down Milling
1. Direction of Cutter Rotation:
○ Up Milling (Conventional Milling): The cutter rotates against the
direction of the feed.
○ Down Milling (Climb Milling): The cutter rotates in the same
direction as the feed.
2. Chip Formation:
○ Up Milling: Chips start thin and get thicker. This can be harder
on the cutter as it can cause more friction and heat.
○ Down Milling: Chips start thick and get thinner. This generally
allows for better surface finish and longer tool life.
3. Surface Finish and Tool Wear:
 ○ Up Milling: Tends to produce a rougher surface finish and
higher tool wear due to the initial contact being a rubbing action.
○ Down Milling: Tends to produce a better surface finish and less
tool wear since the cutting starts with maximum thickness.
K) Classify gear manufacturing methods. Explain gear hobbing
process with a neat sketch.
Gear manufacturing methods can be classified into several categories,
including:
● Gear Cutting: This method involves removing material from a gear
blank to create the desired gear shape. Processes like hobbing,
milling, shaping, and broaching fall under this category.
● Gear Forming: In this method, the gear teeth are formed into the gear
blank without removing material. Processes like forging, casting, and
powder metallurgy are used for gear forming.
● Gear Finishing: This method involves improving the surface finish and
accuracy of gears. Processes like grinding, honing, lapping, and
shaving are used for gear finishing.
Gear hobbing is a common gear cutting process that utilizes a hobbing
machine and a hob to create gears with teeth. Here is an explanation of the
gear hobbing process with a neat sketch:
● Setup: The gear hobbing machine is set up with the workpiece (gear
blank) mounted on the machine spindle and the hob mounted on the
hob arbor.
● Cutting: The hob rotates at high speed while the workpiece rotates
slowly. The hob is fed into the workpiece, and as it moves across the
gear blank, it cuts the teeth into the workpiece.
● Indexing: After each tooth is cut, the workpiece is indexed to the next
position to cut the next tooth. This process continues until all the teeth
are cut.
● Finishing: Once all the teeth are cut, the gear hobbing machine can
perform additional operations like chamfering, deburring, and
finishing to complete the gear.
​