[4] b) Two gating designs for a mould of 50cm 5 25cm 5 15cm are shown below.

The cross-sectional area of the gate is 5cm . Determine the filling time for both the designs.
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Ex/PG/ME/T/128K/165/2012

MASTER OF MECHANICAL ENGINEERING E XAMINATION , 2012

( 2nd Semester )

ADVANCED MANUFACTURING SCIENCE

Time : Three hours Answer any five questions. 1. a) Discuss about Trescas maximum shear stress criterion and Von Mises maximum distortion energy criterion. Hence derive the relationship between tensile and shear yield stresses in each case. b) A cold rolled steel cup with an inside diameter 60mm and thickness 3mm is to be drawn from a blank of radius 40 mm. The shear yield stress and maximum allowable stress of the material can be taken as 210N/mm2 and 600 N/mm2 respectively. i) Determine the drawing force, assuming that the coefficient of friction = 0.1 and the factor for Full Marks : 100

c) Why the section of a sprue reduces downwards ? Explain. 5+10+5=20 8. a) What is centre-line feeding resistance ? b) Write a short note on inspection of castings. 2. c) Describe the method of centrifugal casting. d) What is directional solidification ? Explain it with the help of a diagram. 4+6+6+4=20

calculating the blank holder force = 0.05. ii) Determine the minimum possible radius of the cup which can be drawn from the given blank without causing a fracture. 10+10

a) Derive an expression for forging force per unit length of a strip. State the assumptions made for this purpose. Give necessary sketches. [ Turn over

[2] b) A strip of lead with initial dimensions 24 5 24 5 150 mm is forged to final size of 6 5 96 5 150 mm. Two flat dies are used. The coefficient of friction between the job and the dies is 0.8. Determine the maximum forging force if the average yield stress of lead in tension is 7 N/mm . 3.
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[3] c) Why is aluminium preferred to be done by cold-chamber die-casting process than hot-chamber die casting process ? d) Large parts cannot be manufactured by the centrifuging process. Explain. 6. 3+8+4+5=20

12+8

a) Calculate the size of a cylindrical riser (height and diameter equal) necessary to feed a steel slab casting of dimensions 25 5 25 5 6 cm with a side riser, casting poured horizontally into the mould. b) Why it is necessary to use unpressurized gating system for nonferrous metals ? c) Differentiate between the following casting defects with reference to the causes and method of prevention. i) Cold shut and Misrun 10+4+6=20

a) Two thick slabs are to be joined and the welding process selected for this is electro slag welding process. Justify the selection and discuss the process with suitable sketches. b) Two different pairs of sheets of the same material have to be spot welded. In one pair, there are 25 bridges per cm and the average radius of each bridge is 0.1 mm. The other pair of sheets contains 50 bridges per cm2 with the same average radius of each bridge. Determine the ratio of the voltages to be applied in these two cases in order to generate the same rate of heating per unit area. 10+10 7.
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ii) Blow hole and pinhole porosity.

4.

a) Explain the different chemical heat sources as used in welding. Write the necessary equations in each case. b) Explain and show the potential across the arc space in arc welding process. c) Discuss the different forces acting on a droplet during are welding process. 4+4+12

a) While casting an L-section, a shrinkage cavity is formed, as shown in fig-a. Explain physically why the formation of a shrinkage cavity should be avoided in situations of the type in Fig. b and c.

5.

a) Why are most die-castings not made out of high strength material ? b) With a neat sketch describe a cold chamber die casting process. [ Turn over