Birla Institute of Technology & Science, Pilani

Work-Integrated Learning Programmes Division

Second Semester 2015-2016

Mid-Semester Test
(EC-2 Regular)

Course No. : ET ZC234

Course Title : MANUFACTURING PROCESSES
Nature of Exam : Closed Book
Weightage : 35% No. of Pages =1
Duration : 2 Hours No. of Questions = 5
Date of Exam : 27/02/2016 (AN)
Note:
1. Please follow all the Instructions to Candidates given on the cover page of the answer book.
2. All parts of a question should be answered consecutively. Each answer should start from a fresh page.
3. Assumptions made if any, should be stated clearly at the beginning of your answer.

Q.1 (a) Explain why we should study the crystal structure of metals.

Q.1 (b) List three engineering applications each for which the following physical properties
would be desirable: (1) high density, (2) low melting point, and (3) high thermal
conductivity. [7]

Q.2. Write a short note on following casting processes?

(a) centrifugal casting
(b) squeeze casting [7]

Q.3 (a) Explain the Iron Carbon equilibrium system with figure

Q.3 (b) Explain why there might be a change in the density of a forged product as compared to
that of the cast blank. [7]

Q.4 (a) Explain why one cannot produce a finished forging in one press stroke, starting with a
blank.

Q.4 (b) List the advantages and disadvantages of using a lubricant in forging operations. [7]

Q.5. The desired volume flow rate of the molten metal into the mold is 0.01m 3/min. The
top of the sprue has a diameter of 20mm. And its length is 200mm. What diameter
should be specified at the bottom of the sprue in order to prevent aspiration? What is
the resultant velocity and Reynolds number at the bottom of the sprue if the metal
being cast is aluminium and has a viscosity of 0.004 N-s/m2 and the density of
2700kg/m3? [7]

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