39 real Manufacturing Processes questions from the Mechanical Core bank, as asked in Indian campus drives and tech interviews. Every question has a verified answer and an AI-tutor explanation on placd — free to start.
1. What is Riser?
Junior
A.reservoir of molten metal that feeds a casting during solidification shrinkage and is designed to freeze last
B.the ratio of undeformed to deformed chip thickness, always less than one, from which the shear plane angle is obtained
C.the parent metal adjacent to a weld that was not melted but whose microstructure and properties were altered by the thermal cycle
D.VTⁿ = C, where the exponent n is about 0.1 for HSS, 0.2–0.3 for carbide and 0.5–0.7 for ceramic tools
A.Riser — plastic deformation above the recrystallisation temperature, giving no strain hardening, refined grains and lower forming force
B.Riser — reservoir of molten metal that feeds a casting during solidification shrinkage and is designed to freeze last
C.Riser — removal of material by repeated sparks across a dielectric gap between tool and workpiece, requiring only that the work be electrically conductive
D.Riser — extra dimensions added to a pattern for shrinkage, machining, draft, distortion and rapping (shake)
A.Pattern allowances — the parent metal adjacent to a weld that was not melted but whose microstructure and properties were altered by the thermal cycle
B.Pattern allowances — extra dimensions added to a pattern for shrinkage, machining, draft, distortion and rapping (shake)
C.Pattern allowances — elastic recovery after sheet bending that opens the bend angle, compensated by overbending or bottoming
D.Pattern allowances — plastic deformation above the recrystallisation temperature, giving no strain hardening, refined grains and lower forming force
11. Which term means: "plastic deformation above the recrystallisation temperature, giving no strain hardening, refined grains and lower forming force"?
A.Merchant's circle — the ratio of undeformed to deformed chip thickness, always less than one, from which the shear plane angle is obtained
B.Merchant's circle — the parent metal adjacent to a weld that was not melted but whose microstructure and properties were altered by the thermal cycle
C.Merchant's circle — elastic recovery after sheet bending that opens the bend angle, compensated by overbending or bottoming
D.Merchant's circle — force diagram for orthogonal cutting relating cutting, thrust, shear and friction forces to the shear angle and rake angle
20. Which term means: "work material welded onto the tool tip at low cutting speed on ductile metals, spoiling surface finish as it periodically breaks away"?
A.Built-up edge — plastic deformation above the recrystallisation temperature, giving no strain hardening, refined grains and lower forming force
B.Built-up edge — reservoir of molten metal that feeds a casting during solidification shrinkage and is designed to freeze last
C.Built-up edge — force diagram for orthogonal cutting relating cutting, thrust, shear and friction forces to the shear angle and rake angle
D.Built-up edge — work material welded onto the tool tip at low cutting speed on ductile metals, spoiling surface finish as it periodically breaks away
A.Taylor's tool life equation — removal of material by repeated sparks across a dielectric gap between tool and workpiece, requiring only that the work be electrically conductive
B.Taylor's tool life equation — work material welded onto the tool tip at low cutting speed on ductile metals, spoiling surface finish as it periodically breaks away
C.Taylor's tool life equation — VTⁿ = C, where the exponent n is about 0.1 for HSS, 0.2–0.3 for carbide and 0.5–0.7 for ceramic tools
D.Taylor's tool life equation — plastic deformation above the recrystallisation temperature, giving no strain hardening, refined grains and lower forming force
26. Which term means: "anodic dissolution that removes metal with no tool wear, no burrs and no residual stress, used for hard alloys and turbine blades"?
A.Electrochemical machining — solidification time is proportional to the square of the volume-to-surface-area ratio, the basis for sizing risers
B.Electrochemical machining — anodic dissolution that removes metal with no tool wear, no burrs and no residual stress, used for hard alloys and turbine blades
C.Electrochemical machining — extra dimensions added to a pattern for shrinkage, machining, draft, distortion and rapping (shake)
D.Electrochemical machining — VTⁿ = C, where the exponent n is about 0.1 for HSS, 0.2–0.3 for carbide and 0.5–0.7 for ceramic tools
A.Chip thickness ratio — removal of material by repeated sparks across a dielectric gap between tool and workpiece, requiring only that the work be electrically conductive
B.Chip thickness ratio — VTⁿ = C, where the exponent n is about 0.1 for HSS, 0.2–0.3 for carbide and 0.5–0.7 for ceramic tools
C.Chip thickness ratio — anodic dissolution that removes metal with no tool wear, no burrs and no residual stress, used for hard alloys and turbine blades
D.Chip thickness ratio — the ratio of undeformed to deformed chip thickness, always less than one, from which the shear plane angle is obtained
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