Manufacturing Process

DIME Notes
1) Which of the following statements are true for ultrasonic welding?

1. Productivity of ultrasonic welding is high

2. Thin pieces can be welded to thicker pieces by ultrasonic welding
3. Ultrasonic welds contain foreign inclusions
4. Post cleaning of welds is necessary in ultrasonic welding
5. Preparation required for ultrasonic welding process is very little
a. (1), (2) and (4)
b. (2), (3) and (4)
c. (1), (3) and (5)
d. (1), (2) and (5)
2) The welding process by Metal Inert-Gas (MIG) welding is
a. slower than the welding process by Tungsten Inert-Gas (TIG) welding
b. faster than the welding process by Tungsten Inert-Gas (TIG) welding
c. at same speed as the welding process by Tungsten Inert-Gas (TIG) welding
d. at unpredictable speed
3) Which current is used in Tungsten Inert-Gas (TIG) welding?
a. Only A.C. can be used as welding current
b. Only D.C. can be used as welding current
c. Both A.C. and D.C. can be used as welding current
d. None of the above
4) What is swing over carriage?
a. The maximum diameter of workpiece that can be rotated over the bed ways
b. The minimum diameter of workpiece that can be rotated over the bed ways
c. The maximum diameter of workpiece that can be rotated over lathe saddle
d. The minimum diameter of workpiece that can be rotated over lathe saddle
5) Which of the following is not a part of carriage of the centre lathe?
a. Tool post
b. Apron
c. Compound rest
d. Gear box controls
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6) Consider the following diagram of tailstock.

The part shown in blue color in the below diagram is called as

a. tailstock clamping lever

b. tailstock dead centre
c. tailstock spindle
d. none of the above
7) The centre lathes receive their power through
a. headstock
b. tailstock
c. both a. and b.
d. none of the above
8) Chances of crack propagation are more in
a. cold working process
b. hot working process
c. both a. and b.
d. none of the above
9) In circular drawing process, when the depth of drawing is more than the diameter of
the die, then the process is called as
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a. forced drawing
b. hollow drawing
c. deep drawing
d. all of the above
10) What is the process, in which the metal is caused to flow through a restricted orifice
to create an extremely elongated strip of uniform and comparatively smaller cross-
sectional area, called?
a. Rolling
b. Extrusion
c. Drawing
d. Spinning
11) The foundation of the centre lathe is called as
a. carriage
b. tray
c. base
d. bed
12) When the tool of centre lathe moves perpendicular to the axis of rotation,
a. it produces a cylindrical surface
b. it produces a flat surface
c. it produces a tapered surface
d. none of the above
13) Why are the plasticisers added with polymers?
a. To hold other constituents of plastic together
b. To reduce the cost and enhance the strength and hardness of plastics
c. To improve flexibility and to reduce the temperature and pressure required for moulding of
plastics
d. None of the above
14) The materials such as lead and barium, which are added with polymers to minimize
the effect of heat, sunlight and ozone are called as
a. binders
b. blenders
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c. stabilisers
d. fillers
15) Match the following Tools used in smithy in Group 1 with their Applications in
Group 2 and select the correct option.

1. Sledge hammers, straight, flat and cross peen ------------- A. To nick the bar and to shape the
cold work
2. Smith ball peen hammer ------------------------------------------ B. To make recesses of any shape
in hot metal
3. Punches --------------------------------------------------------------- C. To cut plates to curves
4. Hardie ------------------------------------------------------------------- D. To forge art, bend and shape
the work
5. Anvil ---------------------------------------------------------------------- E. To forge light and medium work
6. Gouge -------------------------------------------------------------------- F. To forge big jobs

a. 1-(E), 2-(F), 3-(A), 4-(B), 5-(C), 6-(D)

b. 1-(E), 2-(F), 3-(B), 4-(A), 5-(D), 6-(C)
c. 1-(F), 2-(E), 3-(A), 4-(B), 5-(C), 6-(D)
d. 1-(F), 2-(E), 3-(B), 4-(A), 5-(D), 6-(C)
16) Castings are usually
a. costlier than forgings
b. cheaper than forgings
c. at the same rate as forging for similar metal
d. none of the above
17) Which of the following options best describes the centre lathes?
a. Machining machines
b. Shaping machines
c. Turning machines
d. None of the above
18) Which type of arc welding is suitable for joining non-ferrous metals?
a. D.C. Arc welding
b. A.C. Arc welding
c. Both D.C. As well as A.C. Arc welding
d. None of the above
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19) Which type of process the machining can be?
a. Cold working
b. Hot working
c. Both a. and b.
d. None of the above
20) Power consumption in D.C. arc welding is
a. less than the power consumption in A.C. arc welding
b. more than the power consumption in A.C. arc welding
c. similar to the power consumption in A.C. arc welding
d. very difficult to calculate
21) The process of combining two or more distinct polymer molecules to form a new
product with different characteristics is called as
a. binding
b. stabilizing
c. filling
d. blending
22) Specific gravity of the plastics is usually
a. less than the specific gravity of metals
b. more than the specific gravity of metals
c. similar to the specific gravity of metals
d. Unpredictable
23) How does the ability of material to withstand unpredictable loads change after
forging?
a. The ability of material to withstand unpredictable loads increases after forging
b. The ability of material to withstand unpredictable loads decreases after forging
c. The ability of material to withstand unpredictable loads does not change after forging
d. Unpredictable
24) Which characteristic of material is used in forging process?
a. characteristics of elasticity of material
b. characteristics of ductility of material
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c. characteristics of plasticity of material
d. none of the above
25) Joint strength in brazing operation is
a. as high as in gas or arc welding
b. not as high as in gas or arc welding
c. higher than that of in gas or arc welding
d. unpredictable
26) What is used as joining medium in brazing operation?
a. Copper-zinc alloy
b. Nickel-silver alloy
c. Lead-tin alloy
d. All of the above
27) Which of the following is a soft solder?
a. Copper-zinc alloy
b. Nickel-silver alloy
c. Lead-tin alloy
d. All of the above
28) Calculate time taken to face a workpiece of 100 mm diameter. The cross feed is 0.2
mm/rev and spindle speed is 200 r.p.m.
a. 10 min
b. 5 min
c. 2.5 min
d. 1.25 min
29) Assume a machining process of taper turning. In this process, a large diameter of
taper is 'D' and it is uniformly decreased to the small diameter of the taper 'd' at the
horizontal length of tapered part of workpiece is 'L'. What is the correct formula for half
of tapper angle (2α / 2)?
a. α = sin–1 ((D – d) / 2L)
b. α = cos–1 ((D – d) / 2L)
c. α = tan–1 ((D – d) / 2L)
d. α = cot–1 ((D – d) / 2L)
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30) Consider the following diagram of machining tool. What is the type of the tool
shown below?

a. Turning tool
b. Facing tool
c. Chamfering tool
d. Parting or necking tool
31) Which of the following characteristics does not affect the properties of plastics?
a. Their molecular structure
b. Their degree of polymerization
c. Both a. and b
d. None of the above
32) Which of the following is an example of thermoplastic material?
a. Camera bodies
b. Automobile parts
c. Electric plugs
d. Electric insulation
33) Which of the following is an example of fusion welding?
a. Atomic hydrogen welding
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b. Flash welding
c. Seam welding
d. Spot welding
34) The metal joined is never brought to a molten stage in
a. pressure welding
b. fusion welding
c. thermit welding
d. none of the above
35) The volume of metal that enters the rolling stand
a. should increase after rolling process
b. should decrease after rolling process
c. should remain same after rolling process
d. unpredictable
36) Worm working or semi-hot working process, which is the plastic deformation of
metal or alloy under conditions of temperature and strain rate, is performed to eliminate
drawbacks of
a. cold working process
b. hot working process
c. both cold and hot working processes
d. none of the above
37) Which plastic materials contain strong cross linkings in their molecular structure?
a. Thermoplastic materials
b. Thermosetting materials
c. Both a. and b.
d. None of the above
38) Thermosetting materials are
a. the plastics which can be softened even after they have set and hardened
b. the plastics which require heat and pressure to mould them into shape
c. both a. and b.
d. none of the above
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39) Which of the following statements is/are true for welding process?
a. General welding equipments are very costly
b. Welding results in residual stresses and distortion of workpiece
c. Two dissimilar metals cannot be joined by welding
d. All of the above
40) The process of joining two pieces of metal with a different fusible metal applied in a
molten state is called as
a. welding
b. soldering
c. both a. and b.
d. none of the above
41) Which of the following are the cold working processes?

(1) Forging
(2) Bending
(3) Squeezing
(4) Pipe Welding
(5) Drawing
a. (1), (2) and (3)
b. (2), (3) and (5)
c. (2), (4) and (5)
d. (1), (2), (3) and (5)
42) Good surface finish and better dimensional accuracy can be achieved in
a. cold working process
b. hot working process
c. both a. and b.
d. none of the above
43) As compared to the arc welding, the gas welding takes
a. considerably less time for the metal to heat up
b. considerably more time for the metal to heat up
c. approximately same time for the metal to heat up as arc welding
d. unpredictable
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44) In resistance electric welding, the current passed through two joining metal pieces
is
a. 230 to 440 volts, at a high amperage
b. 230 to 440 volts, at a low amperage
c. 2 to 8 volts, at a high amperage
d. 2 to 8 volts, at a low amperage
45) The plastics which soften when heat is applied with or without pressure, but
requires cooling to set them to shape are called as
a. thermosofting materials
b. thermosetting materials
c. thermoplastic materials
d. thermostatting materials
46) Which of the following statements are correct for plastic?
1. Plastic is a non-metallic material that can be moulded to any shape
2. Plastic is a natural or synthetic resin
3. Plastic is of organic nature composed of hydrogen, oxygen, carbon and nitrogen
a. only statements 1 and 2 correct, statement 3 is wrong
b. only statements 1 and 3 correct, statement 2 is wrong
c. only statements 2 and 3 correct, statement 1 is wrong
d. all of above statements 1, 2 and 3 are correct
47) Hot working process is the plastic deformation of metal which is carried out
a. at temperature below the recrystallisation temperature
b. at temperature above the recrystallisation temperature
c. at temperature equals to boiling point of water
d. none of the above
48) Mechanical working processes are performed on metals
a. to achieve optimum mechanical properties in the metal
b. to improve the mechanical strength of the metal
c. to make metal dense
d. all of the above
49) Blow holes in casting are caused by
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a. excessive moisture
b. low permeability
c. excessive fine grains
d. all of the above
50) Which casting process has no size and shape limits?
a. Sand casting
b. Shell-mould casting
c. Plaster-mould casting
d. none of the above
51) The productivity of casting process is comparatively
a. lower than the productivity of other automatic processes like rolling
b. higher than the productivity of other automatic processes like rolling
c. similar to the productivity of other automatic processes like rolling
d. unpredictable
52) Which of the following sentences is/are correct for casting process?
a. Casting process is comparatively costly
b. Objects of larges sizes cannot be produced easily by casting process
c. The time required for the process of making casting is quite long
d. All of the above sentences are correct.
53) Match the following contents of green sand in Group 1 with their approximate per
cent in Group 2.

1. Silica -------------------------- A. 5 to 10 per cent

2. Clay --------------------------- B. 2 to 5 per cent
3. Bentonite --------------------- C. 8 to 15 per cent
4. Coal dust --------------------- D. 7 to 8 per cent
5. Water -------------------------- E. up to 75 per cent
a. 1-(E), 2-(C), 3-(B), 4-(A), 5-(D)
b. 1-(E), 2-(A), 3-(B), 4-(C), 5-(D)
c. 1-(C), 2-(D), 3-(B), 4-(A), 5-(E)
d. 1-(C), 2-(A), 3-(B), 4-(D), 5-(E)
54) What is the highest possible percentage of clay contents in loam sand?
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a. 10
b. 20
c. 30
d. 50
55) The sand in its natural or moist state is called as
a. green sand
b. loam sand
c. dry sand
d. none of the above
56) The ability of the moulding sand to withstand the heat of melt without showing any
sign of softening is called as
a. strength or cohesiveness
b. refractiveness
c. collapsibility
d. adhesiveness
57) Permeability can be defined as the property of moulding sand
a. to hold sand grains together
b. to allow gases to escape easily from the mould
c. to withstand the heat of melt without showing any sign of softening
d. none of the above
58) The patterns which are made in two or more pieces are called as
a. solid patters
b. split patterns
c. loose piece patterns
d. none of the above
59) Which of the following is not a requirement of a good pattern?
a. It should be light in weight to handle easily
b. It should be smooth to make casting surface smooth
c. It should have low strength to break it and to remove casting easily
d. none of the above
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60) A model of casting, constructed to use for forming a mould in damp sand, is called
as
a. sand construction
b. pattern
c. cover
d. none of the above
61) Mass production means continuous production without loss of time.
a. True
b. False
62) The objective of utilization of available plant facilities comes under
a. scheduling techniques of production control
b. production planning techniques of production control
c. routing techniques of production control
d. follow-up techniques of production control
63) Scientific management is a systematic approach to manage the enterprise on the
basis of
a. observation
b. experimentation
c. rational decisions
d. all of the above
64) The art of creating industrial relations of any kind, like relation between employers
and employees, is called as
a. organization
b. administration
c. management
d. none of the above
65) What is a disadvantage of automatic control system?
a. It reduces effects of non-linearities
b. It reduces effects of distortions
c. It has a tendency to over-correct errors
d. none of the above
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66) Open-loop control system is
a. less accurate than closed-loop control system
b. more accurate than closed-loop control system
c. equally accurate to closed-loop control system
d. cannot say
67) Match the following elements of control system in Group 1 with their definitions in
Group 2.

1. Control variable --------------------------------- A. A standard signal used for comparison in the

closed-loop system
2. Command ---------------------------------------- B. The quantity of controlled system which can be
directly measured
3. Reference input --------------------------------- C. Any signal other than reference
4. Disturbance -------------------------------------- D. The input which can be independently varied
a. 1-(A), 2-(B), 3-(C), 4-(D)
b. 1-(B), 2-(C), 3-(A), 4-(D)
c. 1-(B), 2-(D), 3-(A), 4-(C)
d. 1-(B), 2-(A), 3-(D), 4-(C)
68) Which of the following production processes is least flexible?
a. Job order production
b. Batch or quantity production
c. Mass production
d. none of the above
69) Which of the following is not a method employed for analysis of manufacturing
system?
a. Statistical techniques
b. Probability models
c. Simulation models
d. Waiting line models
70) The decision of what parts to be manufactured and what parts to be purchased from
market is taken in
a. selection of manufacturing process
b. process planning
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c. analysis of manufacturing system
d. none of the above
71) Why is the selection of right manufacturing process important
a. to produce the product with least cost
b. to produce the product within reasonable time
c. to produce the product at its best possible quality
d. all of the above
72) Gas welding is a type of
a. constant mass process
b. material removal process
c. material addition process
d. none of the above
73) Which of the following is an example of constant mass manufacturing process?
a. Rolling
b. Turning
c. Broaching
d. Sawing
74) In general, any system that produces useful products or services is called as
a. service system
b. production system
c. both a. and b.
d. none of the above
75) Which of the following activities or operations is not related to manufacturing?
a. Product design and development
b. Inventory control
c. Quality assurance
d. None of the above
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