Manufacturing process and Metrology

Time allowed: 3 Hours

ME/5/T4/MPM

Full Marks: 75

Answer question no. 1(compulsory)

Answer any twenty-five questions:

251=25

Write whether the following statements are True or False:

i.

. The property of sand due to which the sand grains stick together is called adhesiveness.

ii.

A sand employed on the faces of the pattern before moulding is called parting sand.

iii.

The purpose of a gate is act as a reserviour for the molten metal.

iv.

The property of a sand due to which it escapes a great amount of steam and other gases is called

Permeability.
v.

In a centrifugal casting method no core is used.

vi.

Cast iron and steel pipes are produced by die casting.

vii.

In powder metallurgy, pressing is also known as compacting.

viii.

Self lubricating bearings can be manufactured by powder metallurgy.

ix.

Permanent magnets can be made from powder metallurgy technique.

x.

Cemented carbide tools and dies are made of casting.

xi.

The process of filling the pores of a sintered part with molten metal is called impregnation.

xii.

In powder metallurgy process, the self lubricating properties achieved by impregnating the
sintered bearing with oil, grease or other lubricating materials.

xiii.

Thermoplastics cannot be reused.

xiv.

The bottles from thermoplastic material are made by blow moulding.

xv.

The long plastic rods, tubes and sheets are made by injection moulding.

xvi.

Polyvinylchloride (PVC) is a thermosetting material.

xvii.

Bevel protector is used for angular measurement.

xviii.

A gauge is used to measure the exact dimension of a component.

xix.

Ring gauges are used to check internal diameter of a job.

xx.

Feeler gauges are used for checking clearances between mating surfaces.

xxi.

In clearance fit there is a negative allowance between the largest possible shaft and the smallest
possible hole.

xxii.

Ultrasonic testing is one of the NDTs.

xxiii.

Sine bar is usually used to measure the length of a job.

Fill in the blanks:

xxiv.

--------------- allowances is given to all vertical surfaces of pattern for easy removal of pattern
from mould cavity.

xxv.

---------------- is called negative allowances in pattern making.

xxvi.

A large size of symmetrical shape of circular section can be made by using -----------pattern.

xxvii.

The surface to be left unmachined is on the pattern by --------------colour.

xxviii.

The surface to be machined is marked on the pattern by -------------colour.

xxix.

Green sand is a mixture of -------% sand and ---------%clay.

xxx.

Core is used to form ------------------in casting.

xxxi.

When a pattern is made of three parts, the intermediate part is called -----------------

xxxii.

A casting defect which results in general enlargement of a casting is known as --------------.

xxxiii.

The compressibility of metal powders is defined as the ratio of initial volume of the powder to the
--------------volume after compaction.

xxxiv.

The process of heating the briquetted component at an elevated temperature in a furnace under
reduced atmospheric conditions is called ------------------------.

xxxv.

In powder metallurgy the process of converting loose powder into green compact is called ---------

xxxvi.

The --------------- is a cold working operation, in which the sintered component is pressed in a die.

xxxvii.

------------------is the process of filling the pores of a sintered part with molten metal.

xxxviii.

The full forms of PVC is ---------------------------------

xxxix.

The micrometer screw has a pitch of -----------mm.

xl.

The length standard may be classified as the line standard and ------------- standard.

xli.

Least dimension which can be measured accurately by a micrometer is called its -----------------

xlii.

Sine bar is used for measuring ------------------

xliii.

A sine bar is specified by the distance between ---------------of two rollers.

xliv.

Plug gauges are used for checking ---------- of many different shapes and sizes.

xlv.

Gear tooth thickness can be checked by --------------.

xlvi.

Measurement of -------------using bevel protectors is direct whereas sine bar make

-------------measurement.

xlvii.

The tightness or looseness between two mating parts is called ----------------

xlviii.

A positive different between the diameters of hole and the shaft is called --------------

xlix.

A limit system is said to be -------------basis when the hole is the constant member.

l.

A limit system is said to be -------------basis when the shaft is the constant member.

Write the correct answer:

li.

An internal difference between the hole dimension and shaft dimension for any type of fit is
called the allowance/tolerance/fit.

lii.

A negative difference the diameters of the hole and the shaft is called tolerance/fit/interference.

liii.

A positive difference between the diameters of the hole and the shaft is called a tolerance/basic
size/clearance.

liv.

Which one of the following instruments is most accurate- vernier caliper/micrometer/slip gauges.

lv.

The combination set can be used to- check angular surfaces/scribe lines/ linear dimension.

lvi.

A sine bar is specified by its total length/the centre distance between the two rollers/the size of
the rollers.

lvii.

Sintering is used for- fixing the tool insert/manufacturing cutting tools/manufacturing powder
metal.

lviii.

The sand is used for making core is green sand/ loam sand/ oil sand.

lix.

Chills are used in moulds to- achieve directional solidification/reduce blow holes/smoothen
metal flow.

lx.

Core prints are provided on patterns to support the core/to locate the core/to locate and support
the core.

Answer any five questions from group-A & Group-B, taking at least two from each group
Group-A
1. a).Discuss different pattern allowances ?

b). what is master pattern? Why double shrinkage allowance put on its dimension discuss with
example?
1+3
2. a). what is a pattern? What are the advantages of wood as pattern material?
b). Define-i). Sand casting ii). Centrifugal casting.
3. a). Classify moulding process. b). what are the desired properties of moulding sand?

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c). Define i). Core print, ii). Chaplet

4. (a) Write short notes on porosity, flowablity, cohesiveness & collapsibility
(b) Write a short note about gating system with labelled sketch.
5. a) Discuss about the process of investment casting by a neat labelled sketch.

6
4
6
6

b). Mention about the advantages and limitations of investment casting.

6. Describe different steps of moulding sand preparation.

10

7. What is core? Describe different steps of core making.

2+8

8. Describe with neat sketch hot chamber die casting and cold chamber die casting method. 10
9. a). what is powder metallurgy ? Describe the stages of powder metallurgy.

b). State advantages of powder metallurgy.

10. a). State the methods of production of metal powder. Discuss atomization and Electrolysis
Processes. b). Define impregnation and infiltration.
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11. Describe: Blending, compacting, pre-sintering and sintering method.

10

Group-B
12. a). Define plastic. Name the different types of plastic. Give example in each case.

b). Explain the following plastic processing methods- i).injection moulding. ii). Blow moulding
and, iii). Calendaring.
13. a). Name some common thermosetting plastics and state uses.
b). state the common properties of plastics.
c). what do you mean by laminating of plastic? State the principle and field of application.
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14. a). What is metrology? What do you mean by line standard and end standard? Give example
in each case.

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b). Draw a neat labeled sketch of an external micrometer. Explain the function of each parts. 6
15. a). State the difference between measuring instrument and gauge.
b). Differentiate between Hole basis system and Shaft basis system with neat sketch.
c). State the purpose of using ring gauge.

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16.a). What do you mean by fit? Name the different types of fit explain each with suitable sketch and
state their field of application.
b). what do you mean by unilateral and bilateral tolerance.

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17. a). Define the terms Allowance and clearance.

b). What do you mean by the term interchangeability?
c). Define nominal size, basic size, actual size and tolerance.

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18. Explain non-destructive testing. Name the different methods of NDT and state their field of
application. Write short notes on ultrasonic testing.

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