[6] b) Briefly discuss the arc structures indicating the different zones in a labelled sketch.

c) Discuss about Metal-Inert gas welding. 7+5+8=20

Ex/PG/ME/T/128K/99/2009

MASTER OF MECHANICAL ENGINEERING EXAMINATION, 2009

( 2nd semester )

ADVANCED MANUFACTURING SCIENCE

Time : Three hours Answer any five questions Answer should be brief & to the point. 1. a) Figure - 1 shows a mould along with the riser for casting a plate 20 cm 5 20 cm 5 5 cm. Determine the area Ag such that the mould & the riser get filled up within 10 sec. after the down spruce has been filled. It should be noted that A3 ? Ag since below the down spruce a flat gate is attached to the casting. Neglect the frictional and orifice effects. Full Marks : 100

Fig. 1

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[2] b) What are the causes of various casting defects ? c) Why is diecasting process employed for low melting metals & alloys ? 2. 12+5+3=20

[5] b) During an orthogonal machining operation on mild steel, the results obtained are t1 = 0.25 mm, t2 = 0.75 mm, w = 2.5 mm, = 0o , FC = 950 N, FT = 475N. i) Determine the co-efficient of friction between the tool and the chip. ii) Determine the ultimate shear stress T of the work material. 10+10=20 6. a) There are two important yield criteria which are used in practice. Explain these yield criteria and state the basic differences between the two. b) Show the relationship between Tensile yield stress and shear yield stress under these two criteria.

a) Determine the solidification time of the following two iron castings when both are poured, with no super heats, into sand at the initial temperature 28oC. i) A slab-shaped casting 10 cm thick

ii) A sphere 10 cm in diameter. The data for iron is

f = 1540oC, L = 272 kJ/kg, m = 7850 kg/m3 and for

sand is C = 1.17 kJ/kg K, K = 0.8655 W/mK, = 1600 kg/m3. b) Discuss about the solidification of metals and alloys.

c) What load is required to deform a cube of 80 mm side, if c) What is CFR ? Explain it. 3. 10+6+4=20 constrained forces on its sides are both 160 tonnes. Yield stress of the cube material is 60 tonnes/cm2. 8+6+6=20 7. a) What are the defects in metal forming process ? Discuss. b) With a neat sketch, describe the cold chamber die-casting process. 8. 10+10=20 a) In a butt welding process using arc welding, the arc power is found 2.0 kVA. The process is used to weld two steel plates, each of 3 m.m. Thickness, as shown in Fig-2. Determine the maximum possible welding speed. It is assumed that the metal transfer is of short circuit type and the arc is on for 85% of the total time. Given
steel

= 1.2 5 105 m2/s, = 43.6 W/moC

a) What are the major defects in butt welds. Give necessary sketches. [ Turn over

K steel

[4] ii) The average shear yield stress during the process. iii) The angle subtended by the deformation zone at the roll centre. iv) The location of the neutral point n . Assume the co-efficient of friction to be 0.1. b) A steel wire is drawn from an initial diameter of 12.7 mm to a final diameter of 10.2 mm at a speed of 90 m/min. The half-cone angle of the die is 6o and the co-efficient of friction at the job-die interface is 0.1. A tensile test on the original steel specimen gives a tensile yield stress 207 N/ mm 2 . A similar specimen shows a tensile yield stress of 414 N/ m at a strain of 0.5.
2

[3] Melting point of steel = 1530 oC Ambient temperature = 35oC. b) Discuss about Soldering and Brazing.

Fig. 2 c) The voltage-length characteristic of a direct current (dc) arc is given by V = (20 + 40l) volts, Where l is the length of the arc in cm. The power source characteristic is approximated by a straight line with an open circuit voltage = 80V and a short circuit current = 1000 amp. Determine the optimum arc lenth and the corresponding arc power. 4. a) A strip with a cross-section of 150 m.m.
5

Assuming a linear stress-strain relationship for the material, determine the drawing power and the maximum possible reduction will the same die. No back tension is applied. 10+10=20 5. a) Determine (i) The proper clearance between the die and the punch, and, assuming that no shear is provided to the punch, also determine the (ii) maximum punching force, and (iii) energy required to punch a hole of 50 mm diameter in a 3-mm-thick steel sheet. The true fracture strain and stress for the material can be taken as 1.75 and 2.1 kN/mm2, respectively.

8+4+8=20 6 m.m is being

rolled with 20% reduction of area, using 400 m.m. diameter steel rolls. Before and after rolling, the shear yield stress of the material is 0.35 kN/mm2 and 0.4 kN/mm2, respectively. Calculate (i) The final strip Thickness. [ Turn over