Unit I

1. What is meant by casting? Give a few examples of casting.

2. Why is casting preferred over other methods of production? Give reasons.
3. Name various constituents of general moulding sand.
4. Discuss the role played by moisture (water) in a moulding sand.
5. What are the main properties of moulding sand?
6. Differentiate between green strength and dry strength
7. Write short notes on:
(a) Green sand, (b) floor sand, (c) Facing sand and (d) dry sand.
8. Differentiate between a ladle and a crucible.
9. What is a pattern? Why are core prints made?
10. Name common materials used for a pattern.
11. Name different types of pattern. Sketch and explain any four of them.
12. What are the cores? What role do they play? How are the cores categorized?
13. Write short notes on the following:
(a) Expendable mould and (b) Permanent mould
14. What are shell moulds? Give their applications.
15. Discuss the function of the following:
(a) Pouring basin, (b) Sprue, (c) riser and (d) Vents
16. Discuss the following types of sand moulding: Bench moulding, floor moulding
and Pit moulding.
17. What are the functions performed by a moulding machine? Why are these
machines used?
18. Discuss the important characteristics of sand mould castings. Compare them with
that of permanent mould castings process.
19. What is permanent mould casting? Why is it so named?
20. Discuss the merits and demerits of permanent mould casting.
21. What is die casting? Discuss the main features of this process.
22. Describe the submerged plunger type hot chamber die casting and cold chamber
die casting machine.
23. Compare the merits and demerits of hot chamber die casting and cold chamber
die casting machine.
24. Name the alloys which are generally die cast.
25. What is an investment casting? Discuss the salient features of investment
casting. What are the advantages and limitations of this process?
26. What is centrifugal casting? What are its specific applications?
27. Write short notes on:
(a) True centrifugal casting
(b) Semi-centrifugal casting
 (c) Centrifuge casting
28. What is meant by fettling of castings? How is it carried out?
29. What types of furnaces are used for melting metals for casting? How is a furnace
selected?
30. What is a cupola? Describe its main features and working.
31. What does a cupola charge consist of? Describe the constructional features of
cupola.
32. Write short notes on:
(a) Arc furnaces
(b) Crucible furnaces
(c) Induction furnaces

UNIT II
1. What is understood by metal forming?
2. Give few examples of metal forming processes.
3. What are cold forming and hot forming? What are the main differences between
the two processes?
4. Give the main features of hot forming operation. Name the metals that are
generally hot formed into various shapes.
5. List down the advantages and disadvantages of hot working of metals.
6. Differentiate between a bloom, slab and billet.
7. What is clod working of metals? Describe the main features of cold working.
8. Name a few major cold working operations. Give their applications.
9. What is cold rolling? How it is different from hot rolling?
10. Write short note on:
(a) Extrusion
(b) Blanking
(c) Piercing
(d) Bending
(e) Roll forming
(f) Stretch forming
(g) Embossing
11. What is the difference between compound die and progressive die?
12. What is sheet metal spinning? How is it done?
13. What are the advantages of plastics over metals?
14. How do thermosetting plastics differ from thermoplastics?
15. Describe the following processing methods:
(a) Compression moulding
(b) Injection moulding
 (c) Extrusion moulding
16. What are the main advantages and limitations of injection moulding?
17. List the typical product applications of compression moulding process.
18. Describe the process of extrusion moulding. Name some products made by this
process.
19. How are welding processes classified?
20. What is arc welding? Name different arc welding processes.
21. What is the principle of shielded metal arc welding process?
22. What are functions of flux coating in SMAW?
23. Explain with a block diagram the principle and working of SMAW.
24. Discuss the SMAW process parameters that influence the weld quality.
25. State the applications of SMAW.
26. What is the principle of GMAW or MIG welding? State its applications.
27. Explain with a block diagram the principle and working of GMAW process.
28. Explain different types of metal transfer in GMAW.
29. State the principle and applications of GTAW or TIG welding process.
30. Differentiate between GTAW and GMAW process?
31. Explain the GTAW setup with the help of a block diagram?
32. Which is the best process to join aluminum and its alloys? Substantiate.
UNIT III
1) Define machining process
2) Differentiate between orthogonal and oblique cutting.
3) List some of the operations that can be performed on the Centre Lathe.
4) Name the four main parts of a Lathe.
5) What are the four major parts of a carriage?
6) Differentiate between live and dead centre.
7) State the use of a steady rest and the difference between the steady rest and
follower rest.
8) Sketch and explain the use of a mandrel.
9) Sketch and explain the various parts of a centre lathe.
10)Sketch a block diagram of a Turret lathe. Name its major parts and explain their
functions.
11) Sketch a block diagram of a Capstan Lathe and label various parts.
12) Differentiate between capstan lathe and turret lathe.
13) Describe various operations that can be performed on a Lathe.
14) Describe various methods of taper turning operations on a lathe.
15) Describe various work holding devices used in a lathe.
16)Explain with a neat sketch the process involved to make a part shown in figure 1.
The length of the job given is 210 mm and dia. is 105 mm. (5)
 Figure 1 All dimensions are in
mm

17) Find the angle at which the compound rest should be set up to turn taper on
the workpiece having a length of 200 mm, larger diameter 45 mm and the
smaller diameter 30 mm.
18) A 150 mm long 12.7 mm dia. Stainless steel rod is being turned to 12.19 mm
dia. on a centre lathe. Spindle speed = 400 rpm, axial speed = 203.20 mm/min.
Calculate cutting speed, Metal removal rate and time to cut.
19) A 10 mm dia. hole is to be drilled in a block of magnesium alloy. The feed is
0.2 mm/rev. and the spindle speed is 800 rpm. Calculate MRR.
20) Calculate the time required to machine a job 170 mm long, 50 mm diameter
to 165 mm length and 40 mm diameter when job rotates at 400 rpm, feed is
0.2 mm/rev. and maximum depth of cut is 2 mm. Take tool approach and
over travel of tool as 8 mm for turning operation.
21) Calculate the minimum time required to machine a job 200 mm long, 160
mm diameter to 196 mm length and 145 mm diameter when job rotates at 400
rpm, feed is 0.2 mm/rev. and maximum depth of cut is 3 mm. Take tool approach
and over travel of tool as 10 mm only for turning operation. Calculate the Metal
removal rate both in turning and facing operations.
UNIT IV
1. Write the applications of shapers.
2. How are shapers specified?
3. Draw a block diagram of a horizontal shaper write about its important parts.
4. How are the jobs held on the table of a horizontal shaper?
5. Sketch and explain the working of a slotter.
6. Sketch and write about the principal parts of a double housing planer.
7. Differentiate between planer and shaper.
 8. List the limitations of planer, shaper and slotter.
9. Discuss the common work-holding devices used on shapers, slotter and planers.
10. Define drilling, boring and counterboring operations.
11. How are the different drilling machines classified?
12. Differentiate between multiple spindle drilling and gang drilling machine.
13. Sketch and describe a radial drilling machine.
14. Name and describe five devices or methods for holding work to be drilled.
15. Compare boring and reaming operation.
16. Name various types of HBM. Discuss them with the help of neat sketches.
17. Sketch a HBM and explain its working.
18. How is the size of boring machine specified?
19. What is the difference between a VBM and a Jig Borer?
20. Define a milling process and a milling cutter.
21. What are types of surfaces that can be produced by milling process?
22. Sketch and contrast the two milling methods of maching flat surfaces.
23. Sketch and explain the working of a plain column and knee type milling machine.
24. Sketch and describe a vertical milling machine.
25. Describe the difference between a horizontal and vertical milling machine.
26. What is the difference between face milling and end milling?
27. Name different types of milling cutters.
28. Differentiate between rough and precision grinding.
29. Sketch and explain the working of an external grinding machine.
30. What are the advantages and disadvantages of centreless grinding?
31. Sketch and explain any one method of external cylindrical centreless grinding.
32. Sketch and explain the various methods of surface grinding.
33. Why are speeds so much higher in grinding than in turning?
34. How are T-slots machined?
UNIT V
1. What is the need for unconventional machining process? Explain.
2. What is the principle of EDM? State its merits and demerits.
3. Name the common dielectric fluid used in EDM. Explain the function of the
dielectric fluid in EDM.
4. What are the requirements of tool material for EDM? Name the common tool
materials.
5. Define an electron beam. Explain why EBM process is performed usually in a
vacuum chamber.
6. List the merits, limitations and applications of EBM process.
7. Explain the principle of LBM with the help of a neat sketch.
8. Contrast LBM and EBM.
9. Discuss the merits, demerits and applications of LBM.
10. What are the different types of lasers used in machining operations.? How much
power density can a laser produce?
11. Explain the method of WJM with the help of a schematic diagram. State its
applications.
12. Explain the method of AJM with the help of a neat sketch.
13. Name the abrasives and carrier gases used in AJM. Write the applications of AJM.
14. Discuss the advantages and disadvantages of WJM.
15. Explain the method of Plasma Arc Machining with the help of a schematic
diagram. State its applications.