VTU Mechanical Engineering (Semester 3)
Manufacturing Process 1
June 2014
Total marks: --
Total time: --
INSTRUCTIONS
(1) Assume appropriate data and state your reasons
(2) Marks are given to the right of every question
(3) Draw neat diagrams wherever necessary


1 (a) With a neat flow diagram, explain the steps involved in metal casting process. Also write the advantages and limitations and applications of metal casting process.
12 M
1 (b) What are pattern allowances? Classify and write a note on draft allowance and distortion allowance with figures.
8 M

2 (a) Name the base sands used in metal casting and briefly discuss the requirement of base sand.
10 M
2 (b) With a neat sketch, explain the working principle of Jolt & Squeeze moulding machine.
10 M

3 (a) Briefly explain the characteristics features of FURAN and ALKYDE type no bake moulding process.
10 M
3 (b) Name the centrifugal casting methods. With neat sketches explain the working of vertical and horizontal type true centrifugal casting process.
10 M

4 (a) With a neat sketch explain the working principle of coreless induction furnace.
10 M
4 (b) With a neat sketch explain the working principle of 3-phase electric arc furnace.
10 M

5 (a) With a neat sketch explain the principle of Laser welding process. Mention its advantages, limitations and applications.
10 M
5 (b) with a neat sketch explain the thermite welding process. Write the advantages and limitations.
10 M

6 (a) With a neat sketch explain the working principle of oxy- acetylene gas welding. Also write the flame characteristics.
12 M
6 (b) Explain Tungsten inert gas are welding process with figure. Mention its advantages.
8 M

7 Write short notes on the following:
a. HAZ in Welding
b. Shrinkage and residual stresses in welding
c. Welding defects and remedies
d. Electrodes.
20 M

8 (a) Distinguish between soldering and brazing. Also discuss briefly the furnace brazing process with figure.
10 M
8 (b) With neat sketches, explain the following types of non-destructive methods of inspection of casting and welding:
i) Eddy current testing ii) Acoustic emission monitoring.
10 M



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