Solution Of Basic manufacturing Process Year 2014 - 15

Utter Pradesh Technical University (UPTU)

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Q.1. Why draft allowance is provided with pattern?                                        (2014 - 15)
Ans. When a pattern is drawn out from a mould the tendency to tear away the edges of the mould in contact with the pattern is greatly decreased, if the surfaces of the pattern are given a slight taper in a direction parallel to which it is being withdrawn. This tapering of the sides of the pattern known as draft, is done to provide a slight clearance for the pattern as it is lifted up. The amount of draft required depends upon the shape and size of the casting, moulding method, the method of production, intricacy of pattern, and whether moulded  by hand or machine.

Q.2. Why Clapper box is use in shaper?                                        (2014 - 15)
Ans. The shaping machine usually cuts on the forward stroke and does not on the backward stroke. So its not required for the tool to be in contact with the work piece when its on the backward stroke. This is ensured by the Clapper box, a device which is hinged to the ram. The lifting of the cutting tool by the clapper box ensures longer tool life and also accidental scratch or other machining defects on the work piece/final product.

Q.3. Which layout is suitable for batch production?                                         (2014 - 15)
Ans. Product layout is most suitable for batch production.

Q.4. Define straight polarity and reverse polarity?                                                 (2014 - 15)
Ans. For arc welding either a.c or d.c. current is used. When d.c. current is used, the workpiece is made positive terminal and electrode is made negative terminal, and the welding setup is said to have straight-polarity.
If the work piece is made negative and electrode positive, the welding set-up is said to have reverse polarity.  

Q.5. Which materials are used to make non-consumable electrodes.    (2014 - 15)
Ans. Non consumable electrode rods are made of tungsten (either pure or containing ionizing additives, such as lanthanum oxide or yttrium oxide), high-grade carbon, or synthetic graphite. 

Q.6. Define creep fracture.                                                            (2014 - 15)
Ans. Go through Q.8. page no. 10.

Q.7. Define some example of ductile materials.                                            (2014 - 15)
Ans. Some common ductile materials are lead, tin, silver, graphite, aluminium, copper, iron, steel etc.

Q.8. In which form the carbon is present in grey cast iron.                                   (2014 - 15)
Ans. Graphite

Q.9. Write the name of any two alloys of copper.                                         (2014 - 15)
Ans. Brass and bronze

Q.10. What do you mean by composite material.                                 (2014 - 15)
Ans. Go through Q.6. page no. 142.

Q.11. What do you mean by heat treatments? Explain the objective of heat treatments and the process.                                                                                 (2014 - 15)
Ans. Go through Q.11 page no. 24.

Q.12. What are desirable properties of moulding sand? Explain each in brief.    (2014 - 15)
Ans. Go through Q.5. page no. 67.

Q.13. What is the principle of gas welding? List the various types of flames generated in oxy-acetylene gas welding and also indicate the application of each.     (2014 - 15) Ans. Go through Q.2 page no. 109.

Q.14. Explain the working principle of rolling. List the different types of rolling mills configurations. Explain any one.                                                                       (2014 - 15) 
Ans. Go through Q.5. page no.42.

Q.15. Explain plastics with their properties. Differentiate between thermosetting plastic and thermo plastic.                                                                                    (2014 - 15) 
Ans. Go through Q.5. page no. 141.

Q.16. What is wrought iron? Explain the properties and applications. How stainless steel does become stainless?                                                                            (2014 - 15) 
Ans. Go through Q.5. page no. 18. and Q.9. page no. 23.

Q.17. What are the major uses of aluminium? List the various types of aluminium alloys. Explain any one.                                                                 (2014 - 15) Ans. Go through Q.2. page no. 29. and Q. 4. page no. 33.

Q.18. Explain with neat sketches, the basic working principle of extrusion. Describe its applications in industry. Name the four extruded products.    (2014 - 15)
Ans. Go through Q.8. page no. 47.

Q.19. Differentiate between hot and cold working of metals.                           (2014 - 15)
Ans. Go through Q. 10 page no. 51.

Q.20. Explain the process of wire drawing with neat sketch.                           (2014 - 15)
Ans. Go through Q.7. page no. 45.

Q.21. With the help of schematic sketch, describe the basic working principle and important parts of drilling machine. List the various allied processes which are performed by use of it.                                                                                                                        (2014 - 15) 
Ans. Go through Q.8. page no. 102.

Q.22. Explain the difference between soldering and brazing.                          (2014 - 15)
Ans. Go through Q.8. page no. 119. and Q. 9 . page no. 120.

Q.23. Explain different types of plant lay out with their advantages and disadvantages and explain the factors which effect the plant layout.                                                (2014 - 15)
Ans. Go through Q.6. page no. 128.
Factors Effecting the Plant Layout: -
When a large industrial undertaking is initially planned a number of important considerations are made before taking a final decision. The common factors effecting this decision are:
1. Availability of space.
2. Availability of power.
3. Availability of water.
4. Availability of raw material.
5. Climatic condition.
6. Means of communication.
7. Marketing facilities for the planned product.
8. Possibilities of utilization and sale of the process wastes and by-products of the planned industry.
9. Effect of ancillary industries. 
10. Availability of skilled and unskilled labour locally.
11. Local taxes and similar other economic considerations.
Once a final decision has been taken, regarding the size and location of the enterprise, the next step is to plan the internal layout of the factory i.e., to planout the sequence of different shops and their location accordingly. The same is generally effected by the following:
1. Specifications of material and product.
2. Manufacturing processes.
3. Type of production.
4. Material handling facilities.
5. System and facilities for storing.
6. Inter-dependability of one shop over the other.
7. Service facilities.
8. Lighting and Ventilation.
After finalizing the above sequence, the internal arrangement of the equipment of different shops is decided next. This is called shop layout. The following factors effect this layout:
1. Size and type of equipment.
2. Number of machines to be installed.
3. Floor area required for working on each machine.
4. Use of individual machine.
5. Power requirements for the machines.
6. Requirements of factory services.
7. Sequence of operations to be followed.
8. Sound and uniform get-up.
9. Accessibility to all the machines.
10. Proper supervision and control.
11. Type of derive used - i.e. group or individual.
12. Safe working conditions.
13. Provision of stores within the shop, i.e., for tools, instruments, finished parts and consumable materials etc.

Q.24. What is the difference between production and productivity?     (2014 - 15)
Ans. Go through Q.8. page no. 130.

Q.25. Explain powder metallurgy with applications.                                      (2014 - 15)
Ans. Go through Q.1. page no. 146.

Q.26. Write short note on press work and its applications.                                 (2014 - 15)
Ans. Go through Q.11. page no. 54.

Q.27. Write short note on ceramics.                                            (2014 - 15)
Ans. Go through Q.3. page no. 134.

Q.28. Write short notes on Cupola furnace.                                           (2014 - 15)
Ans. Go through Q.12. page no. 79.

Q.29. Write short notes on Electroplating and Galvanizing.                            (2014 - 15)
Ans. Go through Q.4. page no. 151.