Q1. Briefly explain the advantages of casting in comparison to other manufacturing processes.

(….marks)

Q2. With the aid of sketch, explain the functions (i) Riser, (ii) Core, (iii) Sprue, (iv) Flask and (v) Cavity
in sand mold. (…..marks)

Q3. A machine element of length 15cm by 12cm wide is to be produced by sand casting. If the cast is
to be free from defects, it should completely fill the 11cm high mold cavity. Determine the
volumetric flow rate of the molten metal and filling time if the melt is poured through a sprue of
6cm high. (….marks)

Q4. Briefly explain the term ‘fluidity’ and factors that affects it. (…..marks)

Q5. With the aid of sketches, briefly distinguish between solidification of pure metal and that of
alloy. (….marks)

Q5. With the aid of sketches briefly discuss four major casting defects. (…..marks)

Q7. Briefly explain the factors that determine castability. (…..marks)

Q8. With the aid of sketches, explain the processes involve in shell molding and highlight its
advantages and disadvantages over sand casting. (….marks)

Q9. What are the advantages and disadvantages of Die-casting process. (….marks)

Q10. With the aid of sketch, briefly explain the following terms (i) Drift (ii) Reduction, (iii) Spreading
during rolling process and show that there is no material loss during plastic deformation
processes. (….marks)

Q11. With the aid of sketches, briefly explain the effect of frictional force in homogeneous and
inhomogeneous deformation processes. (…..marks)

Q12. Explain the important points in the σ – ε curve with respect to production processes.
(…..marks)

Q13. Briefly explain the term ‘work-hardening’ in metal working process. (…..marks)

Q14. With the aid of sketch, briefly explain the following terms as applied to direct extrusion process
in metal forming; (i) Ram (ii) Die (iii) Billet (iv) Mandrel and (v) Container. (…..marks)

Q15. It is required to produce a rod of …..mm diameter from a billet of ……..xm2 cross-sectional area
by extrusion. If a pressure of ………Pa is to be applied to the ram such that the billet moves a
total distance of …..cm in …..seconds, determine the power that will be required to accomplish
this task. Take the strength coefficient and strain-hardening exponent as 0.5 and 0.7
respectively while the empirical constants as 0.8 and 1.3 respectively. ( marks)

Q16. Briefly distinguish between wire and bar drawing in metal forming process. (….marks)

Q17. With the aid of sketch, briefly explain the process involve in wire drawing. Hence, determine the
draw force that will be required to reduce a stock to ……mm diameter from ……mm if the
coefficient of friction between the Die and the stock is 0.3, angle of contact of 300, the
 strengthening coefficient of 0.6, strain-hardening exponent of 0.3, inhomogeneous factor of 1.0,
and empirical constants of 0.4 and 1.2. (…marks)

Q18. With the aid of sketches, briefly explain the following (i) Open-die forging (ii) Impression-die
forging and (iii) Flashless forging. (….marks)

Q19. With the aid of sketches, explain the principles of Oxy-Acetylene welding with respect to
equipment, flame configuration, metallurgical effects, chemical reactions and mechanical
properties. (……marks)

Q20. With the aid of sketches, explain the principles of electric arc welding with respect to
equipment, electrode configuration, metallurgical effects, mechanical properties, voltage and
current relations. (……marks)

Q21. Briefly explain the causes and remedy of major types of welding defects. (…..marks)

Q22. Explain with the aid of sketches the principle of production of engineering components using
powder metallurgy and enumerate the finishing operations on powder metallurgy products.
(…..marks)