Question Bank

FORGING 1.

Give an explanation of the following Items: Recrystallization

Thermo Forging

Soaking Pits

Roll Forging

Blooms

Progressive Piercing

Three-high mill

Piercing

Smith Forging

Tube Extrusion

Board Hammer

Drawing

Impact Forging

Hot Spinning

Press Forging Upset Forging

2.

Why porosity is largely eliminated when metal is hot worked?

3.

What is the re-crystallization temperature?

4.

Describe the difference between hot working and hot finishing

5.

Describe the difference between bars of steel finished by Cold working and Hot working processes

6.

Describe physical properties of steel as a result of Hot working

7.

List the advantage of impact forging

8.

Compare a Forging Press to a Drop Hammer Press and discuss the energy transmitted to the work

9.

What do you understand by Draft on forgings and why it is provided?

10.

Define – Forging, Upsetting, Edging, Bending, Drawing, Punching operation

11.

When will you consider the employment of following methods , Hand forging, Power Forging, Drop Forging

12.

In Drop Forging why is a breakdown impression sometimes used in the Dies ?

13.

What are the advantages of Forging as a manufacturing process ?

14.

What is Hammer Rating and how hammers are selected

15.

How capacity factors determines?

16.

Introduction to Mechanical Working (a) Hot working (b) Cold Working (c) Structure and properties of Materials after such working

17.

Introduction to forging process (a) Smith Forging (b) Hammer forging (c) Drop Forging (d) Press forging (e) Dumpact forging (f) Upset forging (g) Roll Forging

18.

Dies. : Die Blocks, Parting Line, Draft, Allowance, Pre-form impression, Die materials, Die failure, Heat treatment of dies

19.

Forging defects

20.

Typical, Railway forging :-

(a) Type of Materials –Steel, Alloy steel …… (b) Items : Connecting Rods, Shafts, Springs……

21.

Heating furnaces and Hearths

22.

Testing of Wire Ropes

23.

Testing and inspection of Shop products

24

What is the temperature at which component should be located for Forging operation?

25.

What is difference Drop Forging and Pressure forging ? What types of forging machine

are used in Jamalpur Workshop? 26. How are Forging machine operated? 27. What are different types is Forging defects?

MACHINE SHOP THEORY 1.

Name five principal parts of a shaper. Describe their function.

2.

How is the size of a shaper determined?

3.

How should the tool holder be set in the tool post ?

4.

How should the tool head and clapper box be set for shaping a horizontal surface?

5.

State the operations in shaping a rectangular job on the shaper.

6.

What is a vertical shaper?

7.

In what ways does a planer differ from a shaper?

8.

What are the principal parts of a planner?

9.

What is the table of a planner?

10.

What is the housing of a planer?

11.

What is the cross rail of a planer?

12.

What is the tool head of a planer?

13.

Describe the bed of a lathe.

14.

Describe the headstock of a lathe.

15.

Describe the tailstock of a lathe.

16.

What is the carriage of a lathe?

17.

What is the apron of a lathe?

18.

What is the purpose of a compound rest?

19.

What is the feeding mechanism?

20.

What is the thread cutting mechanism?

21.

What is a tool post?

22.

Name eight important cutting tools used on a lathe.

23.

What are tool holders?

24.

What are some of the methods and equipment for holding work on a lathe?

25.

Name the two most commonly usual lathe chucks and give the use of each one.

26.

What is a magnetic chuck?

27.

What equipment is used to hold work between centers on a lathe?

28.

What is the difference between a dead centre and a live centre?

29.

What is a drive plate?

30.

How is the work mounted on centers?

31.

What is turning?

32.

What is facing?

33.

What is boring?

34.

What is the operation of threading?

35.

What are the principal parts of a turret lathe?

36.

What is a vertical turret lathe?

37.

What are the principal parts of milling machine?

38.

What is the function of column?

39.

What is the function of the knee?

40.

What is the purpose of the table?

41.

What is the purpose of the spindle?

42.

What is the overarm in a milling machine?

43.

What is a universal milling m/c?

44.

What is a vertical spindle milling m/c?

45.

What is a precision horizontal boring , drilling and milling m/c?

46.

What is a universal milling attachment?

47.

What is up-milling?

48.

What is down-milling?

49.

Name two material out of which milling cutters are made.

50.

Milling cutters are classified in different ways.

51.

Name three methods of classification.

MACHINIST

1.

Classify the Lathe machines? Discuss how they are specified.

2.

Name the different types of Milling machines?

3.

Name the different types of Cutters used on Milling machine ?

4.

Classify the Boring machines? Name with example.

5.

Name the characteristics of Single point tool.

6.

What is the difference betweens Planning machines and Shaping machine.

7.

Differentiate between Capstan and Turret Lathe.

8.

Name the different kinds of Screw threads used, example with neat sketches. Give examples where they are used.

9.

Write notes on Tolerances of fits.

10.

What do you understand by Interchangeability?

11.

Differentiate between 4-Jaw and 3-Jaw Chucks.

12.

What are the different methods of cutting taper on Lathe machines. Explain any one method.

13.

What do you understand by CNC machine and state their characteristics.

14.

What is the function of Jigs and Fixtures. Explain the difference between them.

15.

What is the use of Coolants and Lubricants

WHEEL SHOP

1.

What are the types of machines used for Wheel turning ? Name them.

2.

What is the sequence of operation in Wheel turning?

3.

What are the types of Wheel set machines?

4.

Give details of Interference machining on Hole basis.

5.

What are the points for rejection of Wheel and Axle?

CMT

1.

What is the organizational set up of Chemist and Metallurgists in Railways?

2.

What types of tests are conducted in CMT/JMP? State the different sections of centralized laboratory.

3.

What are the machines used in preparation of test piece?

4.

What is the function of Polishing disc?

5.

What type of M/c used for UTS? State the particulars of M/s and its capacity

6.

UTS is measured by tensometer , details the particulars of tensometer with its capacity

7.

State the theory of Vickers’s hardness testing method with the specific load application

8.

Why hardness in RB and RC are taken? State its relation with hardness.

9.

State the different methods of Brinell Hardness testing.

10.

What are the methods of estimation of Carbon in plain carbon steel?

11.

How a Carbon percentage in alloyed steel is determined? Name the apparatus.

12.

What is the media to digest copper based alloys?

13.

Why H2SO4 is added to estimate lead in Bronze?

14.

How a micro piece is selected for microscopic examination?.

15.

State the process of microscopic examination, stating the name of instrument used with working details.

CMT 1.

What is the role of CMT organization is Indian Railways

2.

How do you different testing procedures carried out in CMT laboratory?

3.

What do you understand by CMT techniques? What are different types of NDT techniques used in CMT lab./JMP

4.

What do you understand by Ultrasonic testing? Observe ultrasonic testing of axle following different procedures

5.

What do you understand by Magnetic Katich & Dye Penetrate testing?

6.

Which components are tested by magnetic particles and Zyglo (dr penetrate ) test in DPOH Shop

7.

How is soundness of bond between babbit metal and outer shell of suspension bearing checked by ultrasonic testing?

8.

What do you understand by Mechanical testing? What different types of mechanical testing and carried out for quality checking of incoming raw material and product in shops

9.

How is estimation of carbon and surface determined by stockoa apparatus

10.

What are different test carried out for testing quality of rubber and plastic CMT lab?

11.

What are different test carried out in CMT lab for lube oil, FIST oil?

12.

What are the parameter of material determine by performing tensile testing ?

RM & BNS

1. What are the C&W items manufactured in RM/BNS 2. What class of steel used for manufacturing the Die for rivet forging? Where it is made? 3. What treatment is required for Die Block?

PCO

1.

What stands for : IS-3, IS -9 , IS-II, IS-12, IS-16, IS-17, IS-20, IS-24, IS-34

2.

What are the salient features of CLW incentive system? What are the points to be considered while introducing incentive scheme in a shop. Enumerate drawbacks of this scheme and what measure are to be taken in eradicating the misuses of incentive scheme

3.

Why production planning is needed? What are the steps in production planning process?

4.

Planning :

5.

What planning function is carried out in PCO and how?

6.

What steps are taken before a new work order is released? What documents are released along with the work orders?

7.

What are standing work orders? What is the difference between a green work order and a stores work order?

8.

If a new item is to be developed, what steps are required to be taken

9.

What is rate fixing? What is the importance of work study, method study, time study for rate-fixers? How is rating of a worker arrived at?

10.

What is standard time for a job and how is it arrived at?

11.

Incentive

12.

What pattern of incentive is followed in the shop you were attached to?

13.

What is group incentive and how is it different from individual incentive

14.

When worker is allowed to clock Idle time?

15.

Progress

16.

What is the function of progress section? How is it carried out? What interfaces with the shops are used?

17.

What documents are generated by this Section what entries are made in which document by progress section?

18.

Inspection

19.

What is the role of inspectors in the workshop?

20.

What happens if some quantity of manufactured item fails in the section ? How is the raw material used in the defective pieces recouped accounted for ? How the deficiency is made good.

HTS

1.

Define Heat treatment

2.

Why tempering is essential after hardening?

3.

Differentiate between Normalizing and Annealing

4.

What are the purposes of Case hardening? What are the different processes for case Hardening?

WHEEL SHOP

1.

What are the types of machines used for wheel turning, Name them

2.

What is the sequence of operation in wheel turning

3.

What are the types of wheel set machines

4.

Give details of interference machining on hole basis

5.

What are the points for rejection of wheel and axle

WELDING 1.

What is the difference between forge welding and fusion welding ?

2.

The melting temperature of mild steel is ______________ C

3.

Name two principal methods for attaining such temperatures

4.

The temperature of an oxy acetylene flame is _____C

5.

Name two methods of oxy-acetylene flame working

6.

What is the purpose of the pressure regulator

7.

How is the size of the flame varied

8.

On what factor does the delivery pressure from the regulator depend

9.

What do you understand by an oxidizing a neutral and a reducing flame

10.

Where are such flames used

11.

What is built joint

12.

What do you understand by the leftward method of working and the rightward method of working

13.

How do you prepare edges for welding [ Straightening , clean and if necessary veeng the edges ]

14.

What is jack welding

15.

What are the chief difficulties encountered in welding C.I

16.

Why is pre-heating necessary for welding CI

17.

Name tow type of welding Sets

18.

In what materials are electrodes available

19.

Electrodes may have ___________, ___________ or _________ coatings

20.

______________ and __________ coated electrodes have a covering which flux the weld

21.

What purposes does a flux serve?

22.

Why is eye protection require both for oxy-acetylene as well as are welding

23.

On what factor does the p

24.

olarity of welding depend ?

25.

Why pre-heating be dispensed with when welding CI with the electric are process

26.

What do you understand by building up?

27.

What do you understand by surfacing ?

28.

What do you understand by metal interest gas welding ?

THIRD SHOP

Diesel POH Shop 1. What are main design features of WDM2 Locomotives and its speed potential? 2. Describe Bogie of WDM2 Locomotive. What do you understand by terms Co-Co and Trimount? 3. What are various activities followed in POH of WDM2 Locomotive? 4. Why is honey comb itching provided on ALCO Cylinder Liner? 5. What are major differences between 4 Stroke and 2 Stroke Diesel Engine? 6. What are different cycles of operation of 4 stroke engine? 7. How many types of brakes are available on WDM2 Locomotive? 8. Which Valve is used for Locomotive Independent Brake Application? 9. What are the main functions of VAIB Control Valve? 10. Which Main Reservoir is used for Braking System of WDM2 Locomotive? Indicate its Capacity? 11. What is function of Air Dyer on Locomotive? Where is it located? 12. What is the function of Addl. C2 Relay Valve? In which air circuit is it provided? 13. What are the functions of ‘Emergency Brake Valve’? Where is it located on WDM2 Locomotive? 14. What do you understand by Compression Ratio of Diesel Engine? 15. What do you understand by ‘251’ B for ALCO Diesel Engine? 16. What are main functions of Fuel Oil System? 17. How does Fuel Injection Pump (FIP) function?

Name its important components.

Describe its calibration produced for FIP 18. Why is Relief Valve provided in Fuel Oil System? 19. What is the main function of Regulating Valve in Fuel Oil System?

20. What are important maintenance tests carried out for Fuel Injection Nozzle? 21. What do you understand by Turbo supercharging? Explain its advantages. 22. What are various major components of ALCO Turbo supercharger? 23. What do you understand by ‘Turbo run down’ Test ? 24. Why is after cooler provided on Diesel Engine? 25. What are main functions of Lubricating Oil in Diesel Loco? 26. Describe Lube Oil System of WDM2 Locomotive? 27. What is the function of ‘Bye pass’ valve in Lube oil system? 28. What are main components of Lube Oil Pump? 29. How is lubrications of Cam gear undertaken in Diesel Engine? 30. Describe function of Lube oil Cooler of Diesel Locomotives? 31. Describe the function of Water Pump in Cooling Water System? 32. Why are Expansions Tank provided on Diesel Locomotive ? 33. What is function of Low Water Switch (LWS)? 34. How many Temperature Switches are provided on WDM2 Locomotive ? 35. How many Main Bearings are provided on WDM2 Diesel Engine? 36. What are the main functions of WW Governor? 37. How is WW Governor tested? 38. Describe the drive mechanism of WW of the Governor 39. Which types of Expressers are provided on WDM2 Locomotives? 40. Describe the construction details of 6CD4UC Expressor 41. What do you understand by Loading/Unloading of Expressor? 42. How is alignment of Expresser with Diesel Engine undertaken? 43. What is the function of ‘Inter Cooler’ on Expressor ?

44. How is lubrication Expressor carried out? 45. What are main components fitted on ALCO Cylinder Head? 46. Describe overhaul procedure of ALCO Cylinder Head? 47. What do you understand by ‘Blow –by’ Test of Cylinder Head? 48. How is matching of Valve seat with Valve / Undertaken on Cylinder Head 49. What is the function for HP Line in Fuel Oil System? 50. What is function of Camshaft? How are Locations of Camshafts identified on Diesel Engine? 51. What major tests are carried out during Load Box of WDM2 Locomotive? 52. What is the function of Traction Generator? 53. Explain major components of Traction Motor? How is its overhaul carried out? 54. What are the Safety Devices provided on Diesel Locomotive?

STORES 1. What is difference between ‘Stock’ and ‘Non-stock’ Item? 2. What is the procedure for issuing material against various Work Orders ? 3. What happens when material is deposited by Workshop against a Stores work-Order? What do currents are generated is Stores 4. How and when are stocked-items recouped/ What forms/Formats are filled up ? How does the procurement of stock items undertaken ?

MILLWRIGHT SHOP 1. What system of preventive maintenance of M&P is being followed in Jamalpur Workshop? What information system exists to know the breakdown of a Machine ? Analyze the breakdown of Machines in the previous week and comment on the efficacy of the System. 2.

What records are being maintained by the Millwright Shop for predicting failures or for scheduling the Preventive Maintenance? Do they maintain a History sheet of the Machines ? What is the information - retrieval system? What use is made of the past information about the trend of failures/symptoms showed by the Machines ?

3. What is the structure of Millwright Organization? Who maintains the electrical subsystems of the Machine? Who maintains the Electronic Controls of sophisticated Machines in the Workshop?

MCTR 1.

Describe construction details of Jamalpur Jack. Explain design features also.

2.

What do you understand by Synchronization of Jamalpur Jack ? How is it achieved?

3.

Explain the procedure for Load Testing of Jamalpur Jack

4.

Describe the process for manufacture of Gear Box and specified Jamalpur jack.

FOURTH SHOP

Tower Car

1.

What are salient differences between MK II and MKIII Tower Car ?

2.

Describe Constructional details of MK III and MK IV Tower Car. Give difference between the two.

CRANE SHOP

1.

How is capacity of a Crane decided ?

2.

What do you understand by : (i)

Hoisting

(ii)

Slewing

(iii)

Derricking

(iv)

Travelling

3. What is the function of ‘A’ frame on older design 140 T Crane? What arrangements have been provided on new design 140 T Crane? 4. How is Working Radius of 140 T Crane defined? 5. What is ‘Outreach’ of 140-T Crane? 6. How does ‘Lamira’ Brake work in 140 T Crane? 7. What do you undertake by ‘ Axle blocking on 140-T Crane? 8. What different Counter weights have been provided on 140-T Crane? Explain process of pick up and set down of Counter Weights. 9. What are the various Hydraulic Pumps and Motors provided on 140-T Crane?. Explain the function of main Hydraulic Pump 10. What are features of Main Power Rack and Auxiliary Power Pack? 11. What are different Outrigger combination used on 140-T Crane? 2.

How does ‘Safe Low Indicator’ (SLI) System work on 140 T Crane?

3.

How does Brake System function on 140 T Crane? What are different types of Brakes provided on 140 T Crane?

4.

What are various Safety Devices provided on 140 T Crane?

5.

What are various operations carried out for erection (Rigging) of 140T Crane?

6.

Explain working of Pneumatic Circuit of 140 T Crane?

7.

What different types of Wire Ropes are used on 140 T Crane? What attention is being given to Wire Ropes during POH?

8.

What do you understand by ‘Load Chart’ of 140 T Crane?

9.

What are salient features of Bogie of 140-T Crane?

How does Travel gear

engagement/disengagement? 10.

Explain the working of Recovery wrench including Brake on 140 T Crane?

11.

What are different types of Pulleys provided on 140 T Crane?

ACCOUNTS :

1. What do you understand by Work Order? How is costing of Work Order undertaken? 2. What do you understand by ‘Workshop Manufacture Suspense (WMS) and ‘Stores Suspense’ How are they worked out ? 3. How are Issue Notes accounted for ? What is paring of issue note ? 4. What is a ‘Stock Sheet’?

WELDING 1.

What is welding?

2.

What is do you understand by MMAW ?

3.

What the function, flux in welding ? What ingredients are used for manufacture of Welding flux ?

4.

What do you understand by GNAW (Gas shielded metal Arc Welding) ?

5.

What do you understand by MIG, MAG and TIG Welding ? Which process is being used in JMP workshop out of above 3 process

6.

What is the advantage GMAW (Gas Metal Arc Welding) over Shielded metal arc welding (SMAW) ?

7.

What defects are generally found in welding?

8.

What do you understand by Gas welding? In Gas welding used in Jamalpur Workshop

9.

What power sources are used for Arc Welding ?

10.

Which variables/ affect the Weld Quality ?

11.

What criterion is used for selection of electrode in different positions of welding?

12.

What do you undertaken by Codification of Electrodes?

CMT 1.

What is the role of CMT organization in Indian Railways ?

2.

How do you classify different Testing procedures carried out in CMT Laboratory?

3.

What do you understand by NDT techniques? What are different types of NDT techniques used in CMT Laboratory out Jamalpur Workshop ?

4.

What do you understand by Ultrasonic Testing? Observe Ultrasonic Testing of Axle following different procedures.

5.

Which components are tested by Magnetic Particle and ZNGLO (Dye Penetrant ) test in DPOH Shop ?

6.

How is soundness of bond between Babbitt metal and outer shell of Suspension Bearing checked by Ultrasonic Testing?

7.

What do you understand by Mechanical Testing? What different types of Mechanical testing and carried out for Quality checking of incoming raw material and Products in Shops ?

8.

How is estimation of Carbon and Sulpher determined by Strainer’s Apparatus ?

9.

What are different Test carried out for testing quality of Rubber and Plastic CMT Lab?

10.

What are different Test carried out in CMT Lab for Lube Oil and HSD ?

11.

What parameters of material are determine by performing Tensile Testing ?

12.

What you understand by hardness of Material? What are different types of hardness testing Machine available in CMT Lab/Jamalpur ?

13.

What is significance of Impact Test? What are the two different types of Impact Tests?

14.

What do you understand by microscopic examination and Macroscopic Examination?

15.

What is the procedure followed for preparation of Microscopic Sample? Observe microstructure of common metals and alloys in CMT Lab ?.

16.

Why is micro examination important to ascertain the quality of any Metal?

17.

What do you mean by failure of a component? What are different mechanisms of Failure?

18.

How is Failure Investigation carried out in CMT Lab? Observe sequence of Failure investigation of component in CMT Lab. Study Failure Investigation Report available in CMT Lab.

19.

What is the role of CMT organization is Indian Railways

20.

How do you different testing procedures carried out in CMT laboratory?

21.

What do you understand by CMT techniques? What are different types of NDT techniques used in CMT lab./JMP

22.

What do you understand by Ultrasonic testing? Observe ultrasonic testing of axle following different procedures

23.

What do you understand by Magnetic Katich & Dye Penetrate testing?

24.

Which components are tested by magnetic particles and Zyglo (dr penetrate ) test in DPOH Shop

25.

How is soundness of bond between babbit metal and outer shell of suspension bearing checked by ultrasonic testing?

26.

What do you understand by Mechanical testing? What different types of mechanical testing and carried out for quality checking of incoming raw material and product in shops

27.

How is estimation of carbon and surface determined by stockoa apparatus

28.

What are different test carried out for testing quality of rubber and plastic CMT lab?

29.

What are different test carried out in CMT lab for lube oil, FIST oil?

30.

What are the parameter of material determine by performing tensile testing ?

31.

What you Gardens by harden a material? What are different type of hardness testing machine available in CMT lab/Jamalpur ?

32.

What is significance of impact test? what are the two different types of Impact tests?

33.

What do you understand by microscope examination and macroscopic examination?

34.

What is the procedure followed d for preparation of microscopic sample? Observe macrostructure of common metals and alloys in CMT lab.

35.

Why micro examination is important to ascertain the quality of any metal?

36.

What do you mean by failure of a component? What are different mechanism of failure ?

37.

How is failure investigation carried out in CMT Lab? Observe analysis of failure investigation of component in CMT lab. Study failure investigation lay out available in CMT lab.

GREY IRON FOUNDRY 1. What are the properties of Moulding sand? Describe the different tests conducted to determine properties of Moulding sand. 2. What is capacity of Cupola? How is capacity of Cupola related to Melting Zone? 3. What is the ratio of charge of Metal : Coke : Lime stone maintained in Foundry? 4. What size of Coke, Pig Iron / Scrap and Lime stone is maintained in Charge? 5. What thickness of sand bed is maintained in Cupola? 6. What do you understand by Grey Cast Iron? Indicate its properties. 7. What are different types of Cast Iron used in Industry? 8. What do you understand by core print? 9. Is skin dried mould used in Jamalpur Workshop? 10. What type of sand is required for High temperature melt ? 11. What are the binders used in clay free sands? 12. What is applied to give surface finish and strength to a core? 13. What is the name of the Top Box and Bottom box in the Mould? 14. What is the hardness of a mould prepared for C.I.Castings? 15. Why chaplets are used? 16. What is the difference between Green sand and Dry sand? 17. What type of sand is used for Heavy castings and Medium castings? 18. Why a ladle should be red hot and dry? 19. Why molten metal is poured in the sand moulds through Runners and not through Risers? 20. What is the metal recovery (yield) when C.I. is melt in Cupola? 21. What are the parameters to ascertain the melting rate of a Cupola?

22. What is the role of bed height in Cupola operation? 23. In Cupola operation , the first two initial charge are free from flux addition, why? 24. What Metal, Coke and flux ratio is used in Cupola operation for : (a) General Grade CI (b) Grade-20 (c) Grade-25 25. To which specification Cast Iron is produced in GIF. 26. Medium phosphorus Brake blocks are preferred over general Cast iron Brake blocks, why? 27. What are the additives given for manufacture of Medium phosphorus Brake blocks? 28. What is the charge composition of Medium phosphorus Brake blocks? 29. What is the chemistry and hardness of Medium phosphorus Brake blocks? 30. What should be the temperature of molten C.I. at the mouth of tapping hole in Cupola? 31. Why time factor is essential for a molten C.I. from the time of tapping to the pouring time? 32. What precautions should be taken to minimize the temperature loss of a molten metal in a ladle? 33. What mixture should be used in the ladle and spout of a Cupola? Why? 34. What is the function of tuyeres in a Cupola? 35. Metallurgically,

a

Cupola

can

be

divided

into

What are the reactions taking place in a Cupola stage wise? 36. How a lining of a Cupola should be done? 37. To maintain the bed height what action is taken – When bed height is lowered and when raised?

how

many

sections.

38. What type of metal is used to increase the hardness of Cast iron? 39. In a sample of sand made for mould box preparation, what remedial measure will be taken : (a) When Permeability is low and moisture is high. (b) When strength is low and moisture is high. 40. What additional steps are taken to make a mould more permeable? 41. What are the different casting defects? 42. What measures are to be taken to prevent slag inclusion and blow holes? 43. What is the physical nature of the slag and what is your observation based on the nature of the slag ? If slag wool is coming out during the operation of a cupola, if so, what is its significance? 44. After the starting of the blower, how much time is given for natural pre-heating of the charges? 45. What is the relation of the tuyere area and melting zone area? 46. How many charges will hold in the pre-heating zone? 47. How much molten metal should the hearth hold? 48. Why the Coke : Metal is 6:1 in India whereas in U.K -10:1 or 12:1? 49. Why Limestone is added in the charge as a flux? 50. What type of cupola’s lining exists at GIF? 51. What are the percentage loss of Silicon, Manganese & Iron? 52. What are the two elements picked up during melting in a Cupola? 53. What is pattern? What are the different materials used for making pattern? 54. What are the allowances provided in making a pattern? 55. What is core and what is its function?

56. What are the different molding materials used in Foundry? 57. What are the main ingredients used for making molding sand? 58. What are the additives mixed with molding sand and what is its function? 59. Why permeability is important parameter in molding sand? 60. What type of binders are used for making cores? Why the sand in making cores is superior to that of molding sand? 61. What are the important characterizes of sand for making cores? 62. Why cores are always baked? 63. What are three different type of contraction during solidification of molten metal? 64. Which contraction is taken into account by pattern maker? Liquid contraction is compensated by which method? 65. What are the parameters for molding sand for percentage of water & compressive strength? 66. In which area of casting, the riser should be located? 67. What do you mean by sand conditioning and what is the name of the M/C in which sand can be mixed uniformly? 68. What is the method of estimating moisture percentage of molding s is the name of the M/C

STEEL FOUNDRY 1.

How many types of melting furnace is available in Steel Foundry ?

2.

What charge are being charged in 4- Ton. Elect. Arc Furnace ?

3.

Procedure of Steel melting in 4- ton Elect. Arc. Furnace

4.

Steel to which specification is manufactured in Jamalpur Steel Foundry

5.

What is the normal melting time in Elect Arc. Furnace?

6.

What will happen when melting time is prolonged?

7.

What is the Carbon % of Steel melted in CI. II steel? In case when Carbon % in the bath of molten metal comes down, how it is recouped. If Carbon % is found in excess, how it is removed from the melt?

8.

What is the function of Iron ore or Mill scale and Lime stone in Steel making?

9.

Why Ferro Manganese (Fe-Mn.) and Ferro-silicon (FeSi) are added in Steel melt at the end?

10.

What

should

be

the

temp.of

steel

melt

at

the

time

of

tapping?

What instrument is used to measure the temp.of the molten Steel? Why? 11.

What instrument is used to measure the temp, of the molten steel ? Why

12.

Why a ladle should be red hot?

13.

What should be added in the ladle before taping the molten Steel?

14.

Aluminum is suggested to be added in small quantity, why ?

15.

Why a molten metal is supposed to be covered? What type of mixture is used?

16.

Why molten metal is poured in the sand moulds through runners not risers?

17.

What is the function of a Riser?

18.

What tests are carried out to control the chemistry of the bath in Steel melting? How it is done?

19.

What is the metal recovery in Steel casting?

20.

What are the sources of heating and process of heating in 4-ton Arc Furnace and Induction furnace in Steel foundry?

21.

How metal charge is fed in 4-Ton Elect.Arc Furnace?

22.

How selection of scrap is made for melting?

23.

What type of Steel is manufactured in 4-Ton Elect. Arc Furnace?

24.

What is the moulding techniques used in Steel Foundry?

25.

How moisture is tested rapidly in Field laboratory of S.F.?

WELDING 13.

What is welding?

14.

What is MMAW

15.

What the function, flux in welding >? What ingredients are used for ---------- of welding

16.

What do you understand by GNMAW (Gas shielded metal Arc Welding)

17.

What do you understand by MIG, NAG and TIG welding ? Which process is being used in JMP workshop out of above 3 process

18.

What is the advantage GMAW over shielded metal arc welding

19.

What defects are generally found in welding?

20.

What do you understand by Gas welding? In case welding used in Jamalpur Workshop

21.

What power sources are used for arc welding

22.

Which variable affect the weld quality

23.

What criterion is used for selection of electrode in different position of Welding?

24.

What do you undertaken by codification of Electrodes?