Quiz -1
Manufacturing process (MEI102) TOTAL MARKS 25
1) Multiple choice questions Marks (1×5)
i). In limits and fits, the term ‘Allowances’ usually refers to
a) difference between maximum size and minimum size of the shaft
b) difference between maximum size and minimum size of a hole
c) maximum clearance between shaft and hole
d) minimum clearance between shaft and hole
ii).The coordination number of BCC structure is
a) 6 b) 8
c) 10 d) 12
iii). CNC stands for
a) computer numerical control b) computer number control
c) computer numerous control d) calculator numerical control
iv). …… is the element of the indicating device carrying the scale.
a) housing b) transducer
c) dial d) frame
v). Which type of instrument is used for the measurement of the surface roughness
a) stylus b) Vernier caliper
c) tachometer d) odometer
2. Write True and false Marks (1×5)
a) NC machines cannot be used for manufacturing complex parts.
b) Vernier caliper is used to measure the diameter of a shaft.
c) The coordination number of face centered cubic (fcc) is 8.
d) Ceramic molecules are characterized Vander Walls forces.
e) CMM stands for coordinate measuring machine.
3. Questions Marks (3×5)
a) Write 10 safety rules must be followed in the workshop.
b) What is surface roughness? How Ra value can be calculated.
c) A GO/NO GO plug gage is designed to check a hole diameter that is dimensioned 20.00 mm±
0.10 mm, A wear allowance of 2.5% of the total tolerance band is applied to the GO side of the
gage. Determine the nominal sizes of the GO and NO GO sides of the gage.
Quiz -2
Manufacturing process (MEI102) TOTAL MARKS 25
1) Multiple choice questions Marks (1×5)
i). Rotary swaging is used for
a) Flattening the surface
b) Manufacturing nuts and bolts
c) Reducing diameter of round bars and tubes by rotating die which opens and closes
rapidly on the work
d) Manufacturing seamless tubes
ii). Seamless tubes are made by which of the following process
a) cold rolling b) piercing
c) plug rolling d) forging
iii). …… is high energy rate forming
a) upsetting b) explosive fabrication
c) rolling d) forging
iv). Coining is the operation of
a) cold extrusion b) cold forging
c) hot forging d) piercing
v). Long wires are made by
a) swaging b) rolling
c) drawing d) extrusion
2. Write True and false Marks (1×5)
a) External screw threads can be produced by rolling.
b) Collapsible toothpaste tubes are made by direct extrusion.
c) Stretch forming is the process of cold drawing.
d) Extrusion is a forging process.
e) Cold forming increases strength and hardness.
3. Questions Marks (3×5)
a) Define i) Rolling ii) Extrusion iii) Drawing.
b) What is forging? Define different types of forging.
c) A tensile test specimen has a starting gage length = 50 mm and a cross-sectional area = 200
mm2. During the test, the specimen yields under a load of 32,000 N (this is the 0.2% offset) at a
gage length of 50.2 mm. The maximum load of 65,000 N is reached at a gage length of 57.7 mm
just before necking begins. Final fracture occurs at a gage length of 63.5 mm. Determine (a)
yield strength, (b) modulus of elasticity, (c) tensile strength, (d) engineering strain at maximum
load, and (e) percent elongation.
Lab Quiz ( Sheet Metal Working )
Manufacturing process (MEI102) TOTAL MARKS 25
1) Multiple choice questions Marks (1×5)
i) To make a small indentation (centre hole) in sheet metal, a------------------ is used.
a) Pencil
b) Center Punch
c) Needle
d) Scribber
ii) To fasten the sheet metal with steel nail the -------------- is used.
a) Rivet Pliers
b) Pliers
c) Punch
d) Stappler
iii) To bend the sheet metal by 180 degrees a -------------- is used.
a) Carperter’s Hammer
b) Ball peen Hammer
c) Mallet
d) Sledge Hammer
iv) The bench vice is used to -----------the metal sheet firmly during shaping operations.
a) Cut
b) Bend
c) Hold
d) Break
e) None of above
v) Hammers are classified by their weight and type of ---------
a) Head
b) Size
c) Length
d) Height
e) None of above
2. Write true and false Marks (1×5)
a) Files are mainly used to finish metal sheet surface.
b) During drilling the work must be firmly held by a drill chuck.
c) Internal screw threads are cut by hand using twist drills.
d) A drill bit is used to cut circular holes of metal sheet and it is made of High Carbon
Steel.
e) Hacksaw blades are very soft and easily broken.
3. Questions Marks (3×5)
a) Differentiate between punching and blanking with suitable sketches.
b) Explain with suitable sketches Slotting, Perforating, and Notching.
c) A round disk of 150-mm diameter is to be blanked from a strip of 3.2-mm, half-hard
cold-rolled steel whose shear strength is 310 MPa. Determine (i) the appropriate punch and die
diameters, and (ii) blanking force.
Hint:
Clearance allowance value for three sheet metal groups
1. Sand casting is mainly used because
(a) Good dimensional accuracy can be achieved
(b) Any intricate shapes internal or external can be obtained
(c) Better surface finish is achieved
(d) Thin sections can be easily cast.
2. Straight polarity in arc welding is obtained with
(a) Alternating current electrode with electrode being positive
(b) Direct current electrode with electrode being positive
(c) Direct current electrode with electrode being negative
(d) Alternating current electrode with electrode being negative
3. In sandcasting, the lower moulding flask is called as
(a) Cope (b) Cheek (c) Drag (d) Core
4. In sand casting, the upper moulding flask used is called as
(a) Cope (b) Cheek (c) Drag (d) Core
5. Welding is a
(a) Permanent joint
(b) Semi‑permanent joint
(c) Temporary joint
(d) Temporary or Semi‑permanent joint
6. In sand casting, the intermediate moulding flask is called
(a) Cope (b) Cheek (c) Drag (d) Core
7. During solidification, liquid shrinkage in a metal is
(a) Reduction in volume when liquid metal temperature is reduced from pouring
temperature to liquidus temperature
(b) Reduction in volume when solid metal temperature is reduced from solidus to room
temperature
(c) Reduction in volume when solid metal temperature is reduced from liquidus to room
temperature
(d) Reduction in volume when the metal changes from liquid to solid state at the solidus
temperature
8. During solidification process, solid shrinkage in a metal is
(a) Reduction in volume when liquid metal temperature is reduced from pouring temperature
to liquidus temperature
(b) Reduction in volume when solid metal temperature is reduced from solidus to room
temperature
(c) Reduction in volume when solid metal temperature is reduced from liquidus to room
temperature
(d) Reduction in volume when the metal changes from liquid to solid state at the solidus
temperature
9. Shrinkage allowance in sand casting is added to
(a) All linear dimensions
(b) Only the interior dimensions
(c) Only the exterior dimensions
(d) Only to the dimensions that are perpendicular to the parting plane
10. Which of the following pattern allowance can be specified quantitatively
(a) Machining allowance
(b) Shake allowance
(c) Draft allowance
(d) Shrinkage allowance
11. In sand casting, machining allowance is added to
(a) All linear dimensions
(b) Only the interior dimensions
(c) All the dimensions which have tolerances assigned
(d) Only to the dimensions that are perpendicular to the parting plane
12. Electrode for gas metal arc welding of steel is
made of
(a) Tungsten
(b) Steel
(c) Copper
(d) Cadmium copper
13. The main drawback of gray cast iron as a pattern material for making the master pattern is
(a) High density
(b) Good machinability
(c) Low density
(d) High cost
14. The reason for using wood as pattern material is due to its
(a) Long life
(b) Easily shaped
(c) Less distortion due to moisture absorption
(d) Higher strength
15. Permeability of a moulding sand is improved because of
(a) Increasing the moisture content
(b) Coarse grain size
(c) Increasing the compacting pressure
(d) Fine grain size
16. Which of the following can be applied to the mould cavity in order to enhanced the
surface finish of a sand casting,
(a) Coal dust (b) Facing sand (c) Saw dust (d) Iron oxide
17. Fluidity of molten metal is increased by
(a) Increasing the moisture content in moulding sand
(b) Increasing metal temperature
(c) Decreasing the clay content in moulding sand
(d) None of the above
18. What is the desirable property of a core in a sand mould ?
(a) Good green strength
(b) Good collapsibility
(c) Good friability
(d) All of the above
19. Which flame type is usually used to weld high carbon steels during oxy‑acetylene
welding
process is
(a) Natural flame (b) Neutral flame
(c) Oxidising flame (d) Reducing flame
20. Which one of the binders is mostly used in core sands?
(a) Clay (b) Bentonite (c) Linseed oil (d) Starch
21. A chaplet in a sand mould helps to
(a) Support the core during the molten metal pouring
(b) Support the mould from breaking
(c) Support the mould from moving mould walls
(d) Prevent the formation of cold shuts
22. Strength of moulding sand can be increased with
(a) Increasing the moisture content
(b) Coarse grain size
(c) Decreasing the moisture content
(d) Fine grain size
23. Mechanical fastening is a
(a) Permanent joint
(b) Fusion joint
(c) Temporary joint
(d) Temporary or Semi‑permanent joint
24. Arc blow in manual metal arc welding is caused by
(a) The use of AC welding with non‑consumable electrodes
(b) The use of DC welding with consumable electrodes
(c) The use of AC welding with consumable electrodes
(d) None of the above
25. Which one of the binder is used in making the carbon dioxide core?
(a) Clay (b) Sodium silicate (c) Linseed oil (d) Sodium nitrate
26. Welding penetration depth is maximum in which type of welding
(a) DC straight polarity
(b) DC reverse polarity
(c) AC welding polarity
(d) Both a and b
27. Which of the welding process uses non consumable electrode?
(a) Manual metal arc welding
(b) Gas metal arc welding
(c) Gas tungsten arc welding
(d) Submerged Arc Welding
28. For longer weld bead more than 1 m length welding, which of the following process is
preferred?
(a) Manual metal arc welding
(b) Gas metal arc welding
(c) Gas tungsten arc welding
(d) b and c
29. For more metal deposition, which of the welding process is used by keeping the welding
time constant?
(a) Manual Metal Arc Welding
(b) Gas Metal Arc Welding
(c) Gas Tungsten Arc Welding
(d) Submerged Arc Welding
30. Which of the flame is preferred for welding of High carbon steel?
(a) Neutral
(b) Reducing
(c) Slightly carburising
(d) Slightly oxidising
Quiz: III
Machining and un-conventional manufacturing processes
Note: Solve all the questions
Date: 16/2/2021 Time: 6:00 to 6:30PM
Select the correct answers (more than one may be correct) (marks will be given only if all the
correct answers are selected and no wrong answer is selected)
1. Metal cutting is not an action due to:
a. Shear, b. Tension, c. compression, pealing of the chip
2. Turning is an operation of:
a. Orthogonal type, b. oblique cutting, c. straight cutting, d. pealing of the chip
3. During metal cutting, the heat does not generate in the:
a. Primary shear zone, b. secondary shear zone, c. tertiary shear zone, d. machined
area
4. A Vernier scale having 1 mm least count of the main scale and 10 divisions in the Vernier
scale. The least count of the combined scale will be:
a. 0.1 mm, b. 0.01 mm, c. 0.001mm, d. 0.0001mm
5. Which is not a component of a conventional lathe machine:
a. Hard disk, b. outer calliper, c. hammer, d. anvil
Select true and false:
6. Backlash error increases with the life of the machine tool.
7. Electric discharge machining can be done only with electrolyte
8. It is not mandatory for the tool to be harder than the workpiece in the tool based un-
conventional machining
9. Shaper and drilling are not single tool cutting operation
10. Abrasive water jet machining can cut hard and brittle metals.
Subjective type questions:
11. Show the location and name of the tool wear in a single point cutting tool by drawing a
picture.
12. An End milling operation with a two flute cutter is performed with following process
parameters: chip load per tooth: 0.02 mm, depth of cut 1.5 mm, tool rotational speed
3000 rpm. Draw a schematic to show all above process parameters.
13. Draw a schematic of FDM type 3D printer, showing minimum four components.
1. Sand casting is mainly used because
(a) Good dimensional accuracy can be achieved
(b) Any intricate shapes internal or external can be obtained
(c) Better surface finish is achieved
(d) Thin sections can be easily cast.
2. Straight polarity in arc welding is obtained with
(a) Alternating current electrode with electrode being positive
(b) Direct current electrode with electrode being positive
(c) Direct current electrode with electrode being negative
(d) Alternating current electrode with electrode being negative
3. In sandcasting, the lower moulding flask is called as
(a) Cope (b) Cheek (c) Drag (d) Core
4. In sand casting, the upper moulding flask used is called as
(a) Cope (b) Cheek (c) Drag (d) Core
5. Welding is a
(a) Permanent joint
(b) Semi‑permanent joint
(c) Temporary joint
(d) Temporary or Semi‑permanent joint
6. In sand casting, the intermediate moulding flask is called
(a) Cope (b) Cheek (c) Drag (d) Core
7. During solidification, liquid shrinkage in a metal is
(a) Reduction in volume when liquid metal temperature is reduced from pouring
temperature to liquidus temperature
(b) Reduction in volume when solid metal temperature is reduced from solidus to room
temperature
(c) Reduction in volume when solid metal temperature is reduced from liquidus to room
temperature
(d) Reduction in volume when the metal changes from liquid to solid state at the solidus
temperature
8. During solidification process, solid shrinkage in a metal is
(a) Reduction in volume when liquid metal temperature is reduced from pouring temperature
to liquidus temperature
(b) Reduction in volume when solid metal temperature is reduced from solidus to room
temperature
(c) Reduction in volume when solid metal temperature is reduced from liquidus to room
temperature
(d) Reduction in volume when the metal changes from liquid to solid state at the solidus
temperature
9. Shrinkage allowance in sand casting is added to
(a) All linear dimensions
(b) Only the interior dimensions
(c) Only the exterior dimensions
(d) Only to the dimensions that are perpendicular to the parting plane
10. Which of the following pattern allowance can be specified quantitatively
(a) Machining allowance
(b) Shake allowance
(c) Draft allowance
(d) Shrinkage allowance
11. In sand casting, machining allowance is added to
(a) All linear dimensions
(b) Only the interior dimensions
(c) All the dimensions which have tolerances assigned
(d) Only to the dimensions that are perpendicular to the parting plane
12. Electrode for gas metal arc welding of steel is
made of
(a) Tungsten
(b) Steel
(c) Copper
(d) Cadmium copper
13. The main drawback of gray cast iron as a pattern material for making the master pattern is
(a) High density
(b) Good machinability
(c) Low density
(d) High cost
14. The reason for using wood as pattern material is due to its
(a) Long life
(b) Easily shaped
(c) Less distortion due to moisture absorption
(d) Higher strength
15. Permeability of a moulding sand is improved because of
(a) Increasing the moisture content
(b) Coarse grain size
(c) Increasing the compacting pressure
(d) Fine grain size
16. Which of the following can be applied to the mould cavity in order to enhanced the
surface finish of a sand casting,
(a) Coal dust (b) Facing sand (c) Saw dust (d) Iron oxide
17. Fluidity of molten metal is increased by
(a) Increasing the moisture content in moulding sand
(b) Increasing metal temperature
(c) Decreasing the clay content in moulding sand
(d) None of the above
18. What is the desirable property of a core in a sand mould ?
(a) Good green strength
(b) Good collapsibility
(c) Good friability
(d) All of the above
19. Which flame type is usually used to weld high carbon steels during oxy‑acetylene
welding
process is
(a) Natural flame (b) Neutral flame
(c) Oxidising flame (d) Reducing flame
20. Which one of the binders is mostly used in core sands?
(a) Clay (b) Bentonite (c) Linseed oil (d) Starch
21. A chaplet in a sand mould helps to
(a) Support the core during the molten metal pouring
(b) Support the mould from breaking
(c) Support the mould from moving mould walls
(d) Prevent the formation of cold shuts
22. Strength of moulding sand can be increased with
(a) Increasing the moisture content
(b) Coarse grain size
(c) Decreasing the moisture content
(d) Fine grain size
23. Mechanical fastening is a
(a) Permanent joint
(b) Fusion joint
(c) Temporary joint
(d) Temporary or Semi‑permanent joint
24. Arc blow in manual metal arc welding is caused by
(a) The use of AC welding with non‑consumable electrodes
(b) The use of DC welding with consumable electrodes
(c) The use of AC welding with consumable electrodes
(d) None of the above
25. Which one of the binder is used in making the carbon dioxide core?
(a) Clay (b) Sodium silicate (c) Linseed oil (d) Sodium nitrate
26. Welding penetration depth is maximum in which type of welding
(a) DC straight polarity
(b) DC reverse polarity
(c) AC welding polarity
(d) Both a and b
27. Which of the welding process uses non consumable electrode?
(a) Manual metal arc welding
(b) Gas metal arc welding
(c) Gas tungsten arc welding
(d) Submerged Arc Welding
28. For longer weld bead more than 1 m length welding, which of the following process is
preferred?
(a) Manual metal arc welding
(b) Gas metal arc welding
(c) Gas tungsten arc welding
(d) b and c
29. For more metal deposition, which of the welding process is used by keeping the welding
time constant?
(a) Manual Metal Arc Welding
(b) Gas Metal Arc Welding
(c) Gas Tungsten Arc Welding
(d) Submerged Arc Welding
30. Which of the flame is preferred for welding of High carbon steel?
(a) Neutral
(b) Reducing
(c) Slightly carburising
(d) Slightly oxidising
