Manufacturing Processes R23 Imp Questions for Mech Students
Manufacturing Processes/Technology is one of the most essential subjects in the R23 JNTU Mechanical Engineering syllabus. It helps students understand how raw materials are converted into finished products using various casting, forming, machining, welding, and advanced manufacturing techniques.
In this blog, we provide unit-wise important questions, key numericals, and focus topics that will help students prepare effectively for semester exams and interviews.
Manufacturing Processes/Technology Important Questions for R23 JNTU Students (Unit-Wise)
Unit–I: Introduction to Manufacturing and Casting Processes
Key Theory Questions
Define manufacturing and explain its classification based on process type.
What are primary shaping processes? Give examples.
Explain the importance of manufacturing technology in industry.
Define pattern and explain its types.
What are pattern materials and pattern allowances?
Discuss moulding sand composition and properties.
Explain core making and types of cores.
What is gating design? Describe its components.
List casting defects, causes, and remedies.
Explain riser function and design criteria.
Describe shell moulding and investment casting.
What is centrifugal casting? Explain its applications.
Discuss die casting process and types of dies.
Compare permanent mould casting and sand casting.
Explain the solidification process of metals.
Define shrinkage and explain how it affects casting.
Explain directional solidification.
What is Chvorinov’s rule? Write the formula.
Discuss cleaning and inspection of castings.
Explain the steps in the casting process from pattern to finishing.
Numerical Focus Areas
Solidification time using Chvorinov’s rule
Riser and gating design calculations
Pouring time estimation
Casting yield and efficiency
Example Numerical Questions
Compute the solidification time using Chvorinov’s rule for given volume and surface area.
Calculate riser volume required for a defect-free casting.
Estimate the casting yield for a given gating ratio.
Determine pouring time and velocity through the sprue.
Find cooling rate for cast steel and cast iron products.
Unit–II: Metal Forming and Forging Processes
Key Theory Questions
Define metal forming and classify forming processes.
Explain hot and cold working with examples.
Discuss rolling process and types of rolling mills.
What is forging? Explain open-die and closed-die forging.
Describe extrusion and its classification (direct, indirect, impact).
Explain wire drawing and tube drawing processes.
Discuss sheet metal operations – blanking, piercing, bending, and deep drawing.
Define spring-back in sheet metal bending.
Explain residual stresses in formed components.
Compare hot rolling vs cold rolling.
Describe forging defects and their causes.
Explain rolling load and torque calculations.
What are friction and lubrication roles in metal forming?
Discuss extrusion defects and their prevention.
Explain hydrostatic extrusion process.
What are rolling mill arrangements?
Describe slab method for analyzing rolling pressure.
Explain impact extrusion and tube extrusion.
What is drawing ratio and limiting drawing ratio?
Discuss applications of metal forming in industry.
Numerical Focus Areas
Rolling pressure and power calculations
Forging load estimation
Extrusion pressure and reduction ratio
True strain and flow stress
Drawing force and work done
Example Numerical Questions
Calculate rolling torque and power for a steel strip.
Determine extrusion pressure using given area reduction and friction factor.
Compute forging force required for upsetting operation.
Find true strain and flow stress for given deformation.
Estimate friction loss during wire drawing.
Unit–III: Metal Cutting and Machine Tools
Key Theory Questions
Define metal cutting and explain chip formation mechanism.
What are types of chips and their formation conditions?
Explain Merchant’s circle diagram and related equations.
Discuss tool geometry of a single-point cutting tool.
Define rake angle, clearance angle, and cutting edge angle.
Derive Taylor’s tool life equation.
Explain tool wear and its types.
Discuss factors affecting tool life.
Define machinability and explain its influencing factors.
Compare orthogonal cutting and oblique cutting.
Explain coolants and cutting fluids and their applications.
What are cutting speed, feed, and depth of cut?
Discuss machine tool specifications.
Explain lathe operations and lathe accessories.
Describe milling and its types.
What is drilling and explain drill geometry.
Discuss grinding process and grinding wheel selection.
Define surface finish and explain its measurement.
Explain tool signature.
What are non-conventional machining processes?
Numerical Focus Areas
Machining time calculations
Tool life (Taylor’s equation)
Material removal rate (MRR)
Cutting speed, feed, and powerCost analysis and tool economy
Example Numerical Questions
Calculate machining time for a turning operation given feed and speed.
Determine tool life for doubled cutting speed using Taylor’s equation.
Find MRR for a milling operation.
Estimate cutting power and machining cost.
Calculate shear angle and chip thickness ratio.
Unit–IV: Welding and Joining Processes
Key Theory Questions
Define welding and classify welding processes.
Explain gas welding and arc welding principles.
Compare TIG and MIG welding.
What is resistance welding? Explain its applications.
Discuss friction welding and explosive welding.
Explain heat affected zone (HAZ).
What are welding defects and their causes?
Define arc efficiency and weld penetration.
Discuss submerged arc welding process.
Explain brazing and soldering differences.
Describe laser beam welding and electron beam welding.
Explain ultrasonic welding principle.
What are welding positions and symbols?
Discuss preheating and post-weld heat treatment.
Explain shielding gases used in welding.
Describe flux composition and function.
Discuss welding electrodes classification.
Explain weld joint design.
Define distortion in welding and how to control it.
What are safety precautions in welding?
Numerical Focus Areas
Arc efficiency and heat transfer
Welding power and current calculations
Filler consumption estimation
Cooling rate in weld zone
Example Numerical Questions
Calculate heat input per unit length for given current and voltage.
Find arc efficiency for a given welding process.
Estimate welding cost and material usage.
Determine filler wire length for a given joint.
Compute cooling rate in HAZ region.
Unit–V: Advanced Manufacturing and CNC Technology
Key Theory Questions
Define Numerical Control (NC) and CNC systems.
Explain advantages of CNC over conventional machines.
What are G-codes and M-codes? Give examples.
Describe components of a CNC system.
Explain Part Programming structure.
What is DNC (Direct Numerical Control)?
Discuss Adaptive Control systems.
Define Additive Manufacturing (3D Printing) and its types.
Explain Rapid Prototyping and its advantages.
What is Flexible Manufacturing System (FMS)?
Explain CAD/CAM integration.
What are non-traditional machining processes (EDM, ECM, LBM)?
Explain Electric Discharge Machining (EDM) process.
Describe Electrochemical Machining (ECM) principle.
Explain Abrasive Jet Machining (AJM).
Discuss advantages of automation in manufacturing.
What is Industry 4.0 and its relevance?
Explain Robotics in manufacturing systems.
Define computer-aided inspection systems.
Discuss future trends in advanced manufacturing.
Numerical Focus Areas
CNC programming code generation
Tool path and cutting time calculations
Additive manufacturing layer estimation
Power consumption in EDM/ECM
Example Numerical Questions
Write a CNC part program to machine a rectangular profile.
Calculate machining time for CNC milling given feed and rpm.
Determine material removal rate in EDM process.
Estimate energy consumption per component in ECM.
Compute layer count for a 3D printed model.
Conclusion
The subject Manufacturing Processes and Technology is the backbone of mechanical engineering.
For R23 JNTU students, mastering unit-wise theoretical and numerical questions helps secure high marks and build strong technical knowledge for GATE, PSU exams, and industry roles.
Keep practicing consistently — every formula and diagram you revise adds to your engineering confidence.
