MUTHOOT INSTITUTE OF TECHNOLOGY AND SCIENCE

INTERNAL TEST II, APRIL 2017

Fourth Semester

ME 220 MANUFACTURING TECHNOLOGY

ANSWER KEY

Time: 1 hour Maximum Marks: 20

(Draw neat figures wherever necessary)
Part A
(Answer all questions Each question carries 2 marks)
1. Explain with neat sketches Coining and Heading operations. (2 marks)
Coining:
It is a closed die forging process used in minting of coins, medallions and jewelry.
The slug/ work piece is placed in a completely closed die cavity.
The pressure required is 5 to 6 times the strength of material.
Lubricants cannot be applied during coining, because they may entrap in die cavities
and prevent the full reproduction of die surface details.
Coining process can also be used to improve surface finish and to impart the desired
dimensional accuracy. This process is called sizing.
Marking of parts with letters and numbers can be done by coining.

Heading:
Upsetting operation.
The ends of a rod are forged to produce a shape with larger cross section.
Examples: bolts, screws, nails.
The rod may buckle if its length- to- diameter ratio (> 3:1) is very high.
Heading is done in a machine called header.
Header is a highly automated horizontal machine (very noisy) with higher production
rates (100 pieces/ min).
The operation can be carried out cold, warm or hot.
2. What is extrusion? Explain the various extrusion defects. (2 marks)
Extrusion:
It is a process of forcing a metal (pushing) enclosed in a container to flow through
the opening of a die.
The metal is subjected to plastic deformation.
Metal undergoes reduction and elongation during extrusion.
Used to manufacture rods, tubes, variety of circular, rectangular, hexagonal and other
shape both in solid and hollow form, channel, I, Z, T and other sections.
Extrusion may be done hot as well as cold.

Defects:
The three principal extrusion defects are:
1. Surface Cracking
High extrusion temperature, friction and speed can cause surface
cracking and tearing.
These cracks are formed along the grain boundaries.
This defect mainly occur in Al, Mg and Zn alloys.
Can be avoided by lowering the billet temperature and the extrusion
speed.
Surface cracking also occurs at lower temperatures, in which the
extruded product sticks along the die.
When the extruded product sticks on to the die, the extrusion pressure
increases rapidly.
Thus, the product moves forward again and pressure is released.
This cycle is repeated continuously producing periodic
circumferential cracks on the surface known as bamboo defect.
2. Pipe defect
The type of metal-flow pattern in extrusion will draw surface oxides
& impurities toward the center of the billet.
Defect is known as pipe defect, tailpipe, or fishtailing.
Nearly 1/3 rd of the extruded product may contain this type of defect
and have to be cut off as scrap.
Pipe defect can be reduced by having more uniform flow pattern. i.e,
by controlling friction and temperature gradient.
3. Chevron or Internal Cracking
Center of the extruded product can develop cracks, called center
cracking, center-burst, arrowhead fracture, or chevron cracking.
 Centre cracking
Increases with increasing die angle.
Increases with increasing amount of impurities.
Decreases with increasing extrusion ratio and friction.

3. Write short note on rod drawing and wire drawing. (2 marks)

Rod drawing:
The main aim of rod drawing is to:
Straighten it
Size it accurately
Give it a smooth and bright surface
To improve the strength and hardness of the final product
Steps involves
Pickling
Neutralisation
Tapering and lubrication
Gripping and drawing

Wire drawing:
Large coil of nearly 10 mm diameter is subjected to pre- treatment before the actual
drawing process.
Cleaning: This may be done by acid pickling, rinsing, and drying.
Neutralization: Any remaining acid on the raw material is neutralized by
immersing it in a lime bath.
The material is also given a thin layer of lubricant to protect it from corrosion and to
reduce the friction between wire and die.
4. What is clamping? Explain vacuum clamping and magnetic clamping. (2 marks)
Clamping:
A clamp is a device that holds the work piece firmly against the locators and
resists all the forces generated by the cutting action of the tool on the work piece.
The tool designer refers to this action as clamping and the mechanisms used for
this action are known as clamps.
Vacuum clamping:
It is mainly used for securing thin flat sheets which are vulnerable to distortion
under heavy clamping force.
Vacuum clamping provides light clamping.
The holding face is provided with 0.025 mm deep grooves which serves as
vacuum ducts.
The clamping face is circumscribed by rubber seal all around.
The seal segregates the clamping vacuum area from the space outside the seal.
The vacuum pressure used is generally 1 kg/cm2.
The vacuum fixtures are made of aluminium or cast iron.

Magnetic clamping:
Magnetic clamps utilize the attractive force of magnets for clamping purpose.
It is mainly used to hold ferrous metals.
The magnets can be either permanent or electromagnetic.
Electromagnetic clamps are electrically operated, while permanent magnetic
clamps does not require electricity, instead a mechanical lever, handle, or other
device is used to activate the magnet.
Both types of clamps are available in square, rectangular, or round shapes.
Magnetic clamping is mainly used in grinding, light duty milling and turning
operations.

Part B (Answer any 2 questions)

5. What is isothermal forging? Explain the features of an impression die and closed
die forging processes. (6 marks)
Isothermal forging:
Also known as hot- die forging.
The dies are heated to the same temperature as the hot blank (work piece).
Thus, the faster cooling of the work piece at both the ends can be avoided.
The dies for isothermal forging are made up of nickel alloys.
Complex parts with good dimensional accuracy can be forged in one stroke.
These forging are economical for high quantity productions.
Impression die forging:
In impression die forging, the work piece acquires the shape of die cavities while
being forged between two dies.
It is usually carried out a elevated temperatures to lower the force required for
deformation.
The workpiece volume is kept slightly higher than the volume of die cavity.
This extra amount of material may flow outwards during forging and forms flash.
The thin flash cools rapidly and the material inside the die cavity will be
subjected to very high pressure, thereby filling the die cavity.

The quality, dimensional tolerances and surface finish of impression die forging
depends on blank preparation, die surface finish, die wear and effectiveness of
lubricants.
Forces in impression die forging are difficult to predict because of complex shape
of die and each portion of the work piece is subjected to different strains and
temperatures.
=
Where, F is forging force
A is area of forging including flash
is flow stress of material
is pressure multiplying factor
Closed die forging:
In closed die forging, no flash is formed and the work piece is completely
surrounded by the dies.
Correct volume of material and proper die design are essential in order to obtain
a closed die forging of the desired dimensions and tolerances.
Undersized blanks will prevent complete filling of the die cavity and oversized
blanks may cause premature die failure or jamming of the dies.
6. Explain the design features of a typical forging die. What is the importance of pre-
shaping in a forging operation? (6 marks)

Design features of forging die:

a. PARTING LINE
a. It is the line where the two dies meet.
b. For simple symmetric shapes, the parting line is at the center of the forging.
c. For complex shapes, the parting line may be offset and may not lie in a single
plane.
b. GUTTER
a. The flash material is allowed to flow into a gutter through land.
c. FLASH CLEARANCE
a. Flash clearance (between dies) is 3% of the maximum thickness of the
forging.
d. WEB AND RIB
a. A web is a thin portion of the forging that is parallel to the parting line.
b. While a rib is a thin portion that is perpendicular to the parting line.
e. LAND
a. The length of land is usually 5 times that of the flash clearance.
f. DRAFT ANGLE
a. It facilitates easy removal of the part from the die.
b. Ranges between 3 to 10.
c. Generally, internal draft angles are made larger than external ones.
d. Internal draft angle is about 7 to 10 .
e. External draft angle is about 3 to 5 .
g. DIE RADIUS
a. Proper selection of die radius ensures smooth flow of the metal in the cavity
and improves die life.
b. Smaller die radius affects the metal flow and chance of wear increases due to
stress concentration.
c. Small die radius can cause cracks in dies.
h. MACHINING ALLOWANCE & SHRINKAGE ALLOWANCE
 Importance of pre shaping:

The work piece should be shaped before the actual forging is carried out, so that
the material gets properly filled in the die cavities.
Consider the example of forging of a connecting rod.
A round bar stock is used.
The bar is first preformed into an intermediate shape by techniques such as
fullering and edging.
After preforming, the bar is forged into the final shape.
Flash formed on the final product is trimmed off.

7. Explain the main principles of location. (6 marks)

The basic principles of location are:

a. 3-2-1 principle
The bottom of the block is supported against three points.
The rear face of the block rests against two points.
Side of the block rests against a single point.

3 locating pins at the base

o The 3 locating pins at the base can restrict 5 motions.
Rotation along x and y axis (4 motion)
Linear motion along ve z axis (1 motion)
2 locating pins at the rear face
 o The 2 locating pins at the rear face can restrict 3 motions.
Rotation along z axis (2 motion)
Linear motion along +ve y axis (1 motion)
1 locating pin at the side
o The 1 locating pin at the side can restrict 1 motion
Linear motion along ve x axis (1 motion)
Motion along directions 9, 10 and 11 can be restricted using clamps (3
motions).
So, motion in all 12 directions are restricted.
b. Principle of mutually perpendicular planes
While locating a work piece, all the six locating pins should lie in mutually
perpendicular planes.
Locating an object in other than mutually perpendicular plane may cause
lifting of the workpiece due to cutting force.
Also, any foreign material (such as chip) adhering to a plane not at right
angle to the other corresponding plane (say base) may introduce a larger error
during locating a work piece.

c. Principle of least points

It states that, no more points than necessary should be used for locating a job
in a particular plane.
i.e, the number of locating points should be least just to serve the purpose
effectively.
If any extra points are needed, some extra locators may be installed. But it
should be adjustable or removable type.
d. Principle of extreme position
It states that, the locating pins lying on one plane should be kept as far as
possible from one another.
It is because, the locating pins may undergo wear and tear due to continuous
use and will result in deviation of the work piece surface coming into contact
with the pins.
e. Principle of small locating surfaces
It states that, the size of the locators should be as small as possible just
enough for the purpose.
Strong and smaller locators are more effective than bigger locators.
Generally, locating pins are smaller than locating buttons.
Advantages are less time for cleaning, savings in material, less chance of
foreign particle (chips) entrapment etc.
f. Principle of swarf clearance
Easy removal of swarf (chips) is to be ensured and thus blind corners where
chips can accumulate should be avoided.
Accumulation of swarf under work piece in the jig will affect location.
Openings in the jig bottom, under cutting of corners of jig, raising the work
piece on support etc. can avoid difficult situations created by swarf
accommodation.

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