Tech DEGREE CONTINUOUS ASSESSMENT TEST-II, Oct – 2023
Third Semester Department of Mechanical Engineering ME3393 – Manufacturing Process – Answer Key (Regulation 2021) PART A – (10 x 2 = 20 marks) 1. Mention the applications of friction welding. Friction welding can be used to build better industrial rollers, tubes, and shafts. The process is often used to manufacture these subassemblies for CO2 L1RE industrial printers, material handling equipment, as well as automotive, aerospace, marine, and oil applications 2. Name the various methods of Resistance Welding. CO2 L1RE Spot and seam, projection, flash, and upset welding 3. List different defects in welding. Lack Of Penetration or Incomplete Penetration. Lack Of Fusion or Incomplete Fusion. Undercut. Spatter. CO2 L1RE Slag Inclusions. Cracks. Porosity. Overlap. 4. Classify various ARC welding processes. Shielded Metal Arc Welding (Stick Welding) Gas Metal Arc Welding (MIG or MAG Welding) Flux-Cored Arc Welding. CO2 L2UN Gas Plasma Arc Welding. Tungsten Arc Welding (TIG Welding) Submerged Arc Welding. 5. Define Plasma. Plasma is often called “the fourth state of matter,” along with solid, liquid and gas. Just as a liquid will boil, changing into a gas when energy is added, CO2 L2UN heating a gas will form a plasma – a soup of positively charged particles (ions) and negatively charged particles (electrons). 6. Write working principle of Thermit welding. Thermit welding (TW) is a process that uses heat from an exothermic reaction to produce coalescence between metals. The name is derived from CO2 L2UN 'thermite' the generic name given to reactions between metal oxides and reducing agents. 7. State the four major drawbacks of Hot working. Difficulty in Material Handling Heating source has to be provided CO3 L2UN Poor dimension and tolerance control Poor surface finish due to oxidation 8. Explain upsetting in forging. Upset forging involves locally heating a metal bar and then, while holding it firmly with special tooling, applying pressure to the end of the bar in CO3 L2UN the direction of its axis to deform it. The process allows the production of long parts with a forged end. 9. List types of rolling mills based on arrangement. Types of Rolling Mills · 1. Two High Rolling Mills · 2. Three High Rolling CO3 L1RE Mills · 3. Four High Rolling Mills · 4. Cluster Rolling Mill. 5. Tandem Rolling mills 10. Flash less forging – deduce the requirement. Flashless forging is classified as a precise metal forming technology. The main advantages of this technology are the reduction of the flash allowance CO3 L4AN and the shortening of the manufacturing time by eliminating the flash trimming operation.
PART B – (2 x 10 = 20 marks) 11 Explain the method of electron beam welding and give their . applications.
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(OR) 12 Plasma Arc Welding process – Elaborate with neat sketch. .
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13 CO L4A Compare Hot working and Cold working. . 3 N (OR) 14 Discuss Rolling and its types based on arrangement. .
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PART C – ( 1 x 10 = 10 marks) 15 Define Forging, Mention its types, and differentiate between open CO L2U . die forging and closed die forging. 3 N (OR) 16 Hydrostatic Extrusion – Explain the need and advantages of the . process with neat sketch HYDROSTATIC EXTRUSION In hydrostatic extrusion the work piece is held in a sealed chamber surrounded by pressurized liquid. Hydrostatic extrusion is actually a form of direct extrusion. The force delivered through the ram is what pressurizes the liquid. The liquid applies pressure to all surfaces of the work billet. When the ram CO L2U moves forward, it is the force from the incompressible fluid that pushes the 3 N
work through the die, extruding the metal part.
A critical aspect of manufacturing by this process is setup. The metal work billet must first be tapered to fit through the die opening, thus creating a seal. This is done before adding the liquid, in order to prevent leaking. Since the liquid is under great pressure, this taper must be precise to create a robust bond. Many different shapes may be manufactured by this process, using a variety of materials. Liquid pressure from all directions also greatly decreases the chances of buckling of the work.
