Key For the serial test-2

Subject Name
Manufacturing Technology - I
Sub. Code ME 6302
1. What does angle of bite in rolling?
The capture of the metal by the rolls and the stability of the process result from the frictional forces arisin
g on the contact surface between themetal and the rolls.The tangent of the angle of bite
is
the angle between the radii extended from the roll axes to pointsA and B and
which
must not exceed the coefficient of friction: tan . When a very smooth surface is not requiredthe surfa
ce roughness is added to the rolls in order to increase the angle of bite and, thus, of draft.
In practice, the angles of bite are 20-26 in hot rolling with smooth rolls, 27
34 in hot rolling with notched surfaces, and 26 in cold rollingwith a lubricant.

2. Define upsetting and drawing down in forging.

Upsetting
This is applied to increase the cross seat ional area of the stock at the expanse of the length. To achieve
the length of upsetting force is applied in a direction parallel to the length axis, For example forming of a
bolt head
Drawing down
This is the operation in which metal gets elongated with a reduction in the cross sedation area. For this, a
force is to be applied in a direction perpendiaulant to the length axis.
3. What are the differences between hot working cold working? Any four
COLD WORKING

HOT WORKING

Below the recrystallization temperature

Metals above the recrystallization temperature

No heating

Heating is required

Bettter surface finish

Poor surface finish due to scaling

Better dimensional control

Poor dimensional control

Better reproducibility and interchangeablity

Poor reproducibility and interchangeablity

Better strength, fatigue, and wear properties of

material

Poor strength, fatigue, and wear properties of material

Contamination problems are almost negligible

Contamination problems are present

Strain hardening occurs

No strain hardening

Heavier and more powerful equipment

Lesser forces are required

Handling and maintaining of cold metal is easy

Handling and maintaining of hot metal is difficult

Longer life of tooling and equipment

Lower life of tooling and equipment

4. State the characteristics of the materials that can be drawn into wire.
Ductility, draw ability, no necking, stretch ability, grain size
5. Differentiate extrusion and forging.( Diagram may be included)
Forging is a process in which material is shaped by the application of localized compressive forces
exerted manually or with power hammers, presses or special forging machines.
Extrusion is a process used to create objects of a fixed cross-sectional profile. A material is pushed
through a die of the desired cross-section.
6. Name the types of forging machines. (Simple Diagram may be included)

Drop hammer,screw press, crank press, hydraulic press.

7. List some applications where the extrusion is used.
Rod extrusion(circular,square), shape extrusion(L.I angles)
8. What is the principle of resistance welding?
Resistance welding is a thermo-electric process in which heat is generated at the interface of the parts to
be joined by passing an electrical current through the parts for a precisely controlled time and under a
controlled pressure (also called force). The name resistance welding derives from the fact that the
resistance of the workpieces and electrodes are used in combination or contrast to generate the heat at
their interface. Q = I2 Rt
Q = heat generated, joules I = current, amperes R = total resistance of the workpiece, ohms t = total
duration of heat input (weld time), seconds
9. How does brazing differ from soldering?Any three
S.No
Soldering
Brazing
Soldering joints are weakest joints out of three. Brazing are weaker than welding joints but
1
Not meant to bear the load. Use to make stronger than soldering joints. This can be used
electrical contacts generally.
to bear the load up to some extent
Temperature requirement is up to 450 degree Temperature may go to 600 degree Centigrade
2
Centigrade in Soldering joints.
in Brazing joints.
Heating of the work pieces is not required
Work pieces are heated but below their melting
3
point
No change in mechanical properties after May change in mechanical properties of joint
4
joining.
but it is almost negligible
Cost involved and skill requirements are very Cost involved and sill required are in between
5
low
others two.
No heat treatment is required.
No heat treatment is required after brazing.
6
Preheating of workpieces before soldering is Preheating is desirable to make strong joint as
good for making good quality joint.
brazing is carried out at relatively low
7
temperature.
10. Brief the friction welding by simple diagram.
Friction welding (FRW) is a solid-state welding process that generates heat through
mechanical friction between workpieces in relative motion to one another, with the addition of a lateral
force called "upset" to plastically displace and fuse the materials.

Part B - (2 X16=32 Marks)

11 i. Discuss the sequence of operations and the advantages of the friction welding process(8).
(4+4)

Advantages

Enables joining of dissimilar materials normally not compatible for welding by other joining
methods.
Creates narrow, heat-affected zone
Consistent and repetitive process of complete metal fusion
Joint preparation is minimal saw cut surface used most commonly
Faster Turn-around Times compared to the long lead time of forgings, which are currently 6
months or longer.
Greatly increases design flexibility choose appropriate material for each area of a blank
Suitable for diverse quantities from single prototypes to high-volume production
No fluxes, filler material, or gases required
Environmentally friendly process no fumes, gases, or smoke generated
Solid state process no possibility of porosity or slag inclusions
Creates cast or forge-like blanks without expensive tooling or minimum quantity
requirements
Reduces machining labor, thereby reducing perishable tooling costs while increasing capacity
Full surface weld gives superior strength in critical areas
Reduces raw material costs in bi-metal applications. Expensive materials are only used where
necessary in the blank
ii. How is the square billet converted into a round rod using rolling process? Explain the
sequence of operations with neat sketches(8).(4+4)

OR
12 i. Explain the EBM welding process with neat sketch(8). (4+4)
Electron Beam Welding (EBW)
The electron beam welding machine is made up of three main components: beam generation, beam
manipulation and forming and working chamber. These components may also have separate vacuum
systems, The electrons are accelerated by high voltage between the cathode and the pierced anode. A
modulating electrode, the socalled Wehnelt cylinder, which is positioned between anode and cathode,
regulates the electron flow. Dependent on the height of the cut-off voltage between the cathode and the
modulating electrode, is a barrier field which may pass only a certain quantity of electrons. This happens
during an electron excess in front of the cathode where it culminates in form of an electron cloud. Due to
its particular shape which can be compared to a concave mirror as used in light optic, the Wehnelt
cylinder also effects, besides the beam current adjustment, the electrostatic focussing of the electron
beam.
The electron beam which diverges after having passed the pierced anode, however, obtains the power
density which is necessary for welding only after having passed the adjacent alignment and focussing
system. One or several electromagnetic focussing lenses bundle the beam onto the workpiece inside the
vacuum chamber.

A deflection coil assists in maintaining the electron beam oscillating motion. An additional stigmator coil
may help to correct aberrations of the lenses. A viewing optic or a video system allows the exact
positioning of the electron beam onto the weld groove.
The core piece of the electron beam welding machine is the electron beam gun where the electron beam is
generated under high vacuum. The tightly focussed electron beam diverges rapidly under atmospheric
pressure caused by scattering and ionisation development with air. As it would, here, loose power density
and efficiency, the welding process is, as a rule, carried out under medium or high vacuum. The necessary
vacuum is generated in separate vacuum pumps for working chamber and beam gun. A shut-off valve
which is positioned between electron gun and working chamber serves to maintain the gun vacuum while
the working chamber is flooded.
In universal machines, the workpiece manipulator assembly inside the vacuum chamber is a slide with
working table positioned over NCcontrolled stepper motors. For workpiece removal, the slide is moved
from the vacuum chamber onto the workpiece platform. A distinction is made between electron beam
machines with vertical and horizontal beam manipulation systems.
The energy conversion indicates that the kinetic energy of the highly accelerated electrons is, at the
operational point, not only converted into the heat necessary for welding, but is also released by heat
radiation and heat dissipation. Furthermore, a part of the incident electrons (primary electrons) is subject
to backscatter and by secondary processes the secondary electrons are emitted from the workpiece thus
generating X-rays.
The impact of the electrons, which are tightly focussed into a corpuscular beam, onto the workpiece
surface stops the electrons; their penetration depth into the workpiece is very low, just a few m. Most of
the kinetic energy is released in the form of heat. The high energy density at the impact point causes the
metal to evaporate thus allowing the following electrons a deeper penetration.
This finally leads to a metal vapour cavity which is surrounded by a shell of fluid metal, covering the
entire weld depth, . This deep-weld effect allows nowadays penetration depths into steel materials
of up to 300 mm, when modern high vacuum-high voltage machines are used. The diameter of the cavity
corresponds approximately with the beam diameter. By a relative motion in the direction of the weld
groove between workpiece and electron beam the cavity penetrates through the material, At the front side
of the cavity new material is molten which, to some extent, evaporates, but for the most part flows.

ii. Describe the principle of rolling. Write the various kinds of rolling mills along their
applications (8). (4+4)
Various Roll Configurations (a) Two-high (b) Three-high (c) Four-high (d) Cluster mill (e) Tandem
mill

13 i. With the aid of neat sketch explain the wire drawing process (8). (4+4)
WIRE DRAWING
By successive drawing operation through dies of reducing diameter the wire can be reduced to a very
small diameter. Annealing before each drawing operation permits large area reduction. Tungsten Carbide
dies are used to for drawing hard wires, and diamond dies is the choice for fine wires.

Wire drawing is primarily the same as bar drawing except that it involves smaller diameter
material that can be coiled. It is generally performed as a continuous operation on draw bench like the one
shown in fig

Wire drawing on a continuous draw block.

The rotating draw block provides a continuous pull on the incoming wire.
ii. Discuss the forward and backward extrusion techniques and list their applications (8). (4+4)
Direct extrusion: Direct extrusion, also called forward extrusion, is a process in which is the billet moves
along the same direction as the ram and punch do. Sliding of billet is against stationary container
wall.Friction between the container and billet is high. As a result, greater forces are required. A dummy
block of slightly lower diameter than the billet diameter is used in order to prevent oxidation of the billet
in hot extrusion. Hollow sections like tubes can be extruded by direct method, by using hollow billet and
a mandrel attached to the dummy block.
Extrusion force, which is the force required for extrusion, in direct extrusion, varies with ram travel as

shown in figure above. Initially the billet gets compressed to the size of container, before getting
extruded. Also, initially static friction exists between billet and container. As a result the extrusion
pressure or force increases steeply as shown. Once the billet starts getting extruded, it length inside the
container is reduced. Friction between billet and container now starts reducing. Therefore, extrusion
pressure reduces. The highest pressure at which extrusion starts is called breakthrough pressure. At the
end of the extrusion, the small amount of material left in the container gets pulled into the die, making the
billet hollow at centre. This is called pipe. Beyond pipe formation, the extrusion pressure rapidly
increases, as the small size billet present offers higher resistance. As the length of the billet is increased,
the corresponding extrusion pressure is also higher because of friction between container and billet.
Therefore, billet lengths beyond 5 times the diameter are not preferred in direct extrusion. Direct
extrusion can be employed for extruding solid circular or non-circular sections, hollow sections such as
tubes or cups.

Indirect extrusion (backward extrusion) is a process in which punch moves opposite to that of the billet.
Here there is no relative motion between container and billet. Hence, there is less friction and hence
reduced forces are required for indirect extrusion. For extruding solid pieces, hollow punch is required. In
hollow extrusion, the material gets forced through the annular space between the solid punch and the
container. The variation of extrusion pressure in indirect extrusion is shown above. As seen, extrusion
pressure for indirect extrusion is lower than that for direct extrusion. Many components are manufactured
by combining direct and indirect extrusions. Indirect extrusion can not be used for extruding long
extrudes

OR
14 i. Write short notes on hydrostatic extrusion and impact extrusion (8).
Hydrostatic extrusion: In hydrostatic extrusion the container is filled with a fluid. Extrusion pressure is
transmitted through the fluid to the billet. Friction is eliminated in this process because of there is no
contact between billet and container wall. Brittle materials can be extruded by this process. Highly brittle
materials can be extruded into a pressure chamber. Greater reductions are possible by this method.
Pressure involved in the process may be as high as 1700 MPa. Pressure is limited by the strength of the
container, punch and die materials. Vegetable oils such as castor oil are used. Normally this process is
carried out at room temperature. A couple of disadvantages of the process are: leakage of pressurized oil
and uncontrolled speed of extrusion at exit, due to release of stored energy by the oil. This may result in
shock in the machinery. This problem is overcome by making the punch come into contact with the billet
and reducing the quantity of oil through less clearance between billet and container. Hydrostatic extrusion
is employed for making aluminium or copper wires-especially for reducing their diameters. Ceramics can
be extruded by this process. Cladding is another application of the process. Extrusion ratios from 20 (for
steels) to as high as 200 (for aluminium) can be achieved in this process.

Impact extrusion: Hollow sections such as cups, toothpaste containers are made by impact extrusion. It is
a variation of indirect extrusion. The punch is made to strike the slug at high speed by impact load. Tubes
of small wall thickness can be produced. Usually metals like copper, aluminium, lead are impact
extruded.
ii. Describe the defects in forging and rolling with suitable sketches (8).

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