NivaarExam Prep

23-Ind-B2 Manufacturing Processes

Worked solutions to 11 past sittings (2013–2019), 77 questions. Pick a sitting, or start from a topic below.

Topics across the sittings

Topics that come up in more than one sitting, taken from the headings of our worked solutions. A topic counts once per sitting.

Questions by sitting

December 2019

  1. Question 1: Forging Flash, Injection-Molding Fundamentals, and Commercial Viability of Manufacturing Technology
  2. Question 2: Identifying Casting Technology from Surface Finish, Parting Line, and Defects
  3. Question 3: Why Solidification Shrinkage Produces a Core Cavity Rather Than Deforming the Part
  4. Question 4: Sprue/Runner/Gate Freeze Order, Typical Shrinkage Values, and Continuous-Fiber Composites
  5. Question 5: Estimating Injection-Molding Solidification Time for a Thin vs. a Thick Part
  6. Question 6: Why Progressive Dies Are Recommended in Stamping
  7. Question 7: Forging-then-Machining Process Sequence for a Connecting Rod, and Drilling a Long Hole

December 2018

  1. Question 1: Classifying Manufacturing Processes — Net-Shaping, Additive, and Cutting Technologies
  2. Question 2: Casting Post-Processing, Riser Function, and Expendable-Mold Processes
  3. Question 3: Investment-Casting Soundness and Die-Casting Weakness
  4. Question 4: Injection-Molded Part Thickness — Cost and Performance Trade-Offs
  5. Question 5: Residual Stress in Injection Molding from a Lower Mold Temperature
  6. Question 6: Machining versus Forming for Metal-Part Production
  7. Question 7: Recommended Process for a Hollow Aluminum Elbow Pipe

May 2018

  1. Question 1: Density, Melting-Temperature, and Thermal-Conductivity Ranges of Engineering Materials
  2. Question 2: Surface Roughness R a — Definition, Calculation, and Typical Casting Values
  3. Question 3: Investment Casting Process Steps and Slow Heat Transfer During Solidification
  4. Question 4: Injection-Molding Warpage, Injection Pressure, and Packing
  5. Question 5: Composites Processing — Filament Winding, Sheet Molding Compound, and Spray-Up
  6. Question 6: Forging/Stamping vs. Casting for Crankshafts, Work-Hardening, and Hot Working
  7. Question 7: Orthogonal Cutting Schematic, Rake-Angle Limits, and Chip Breakers

December 2016

  1. Question 1: Non-Ferrous Alloy Characteristics, Plastics vs. Metals, and Trends in Plastics Development
  2. Question 2: Casting Process Selection, S​hell-Molding, and Permanent-Mold Casting
  3. Question 3: Metal Chip Types, Built-Up Edge, and the Orthogonal-Cutting Shear Angle
  4. Question 4: Factors in Metal Cutting, Tool Wear/Finish/Machinability, and Current Trends
  5. Question 5: Grinding Operation Characteristics, Design Considerations, and the Economics of Surface Finish/Accuracy
  6. Question 6: Residual Stress in Welding, Joint/Process Selection Factors, and Future Trends in Welding
  7. Question 7: Statistical Process Control, Acceptance Sampling/AQL, and the Deming and Taguchi Methods

May 2016

  1. Question 1: Manufacturing Engineer Responsibilities, Material Selection Factors, and the Annealing Process
  2. Question 2: Plastics vs. Metals, Polymer Additives, and Thermoplastics/Thermosets/Elastomers
  3. Question 3: Drilling Cutting Time, and the Action and Effects of Cutting Fluids
  4. Question 4: Forming/Shaping Process Characteristics, Forging Steps, and Forging Trends
  5. Question 5: Resistance Welding, Spot vs. Seam Welding, and Oxyfuel Gas Cutting
  6. Question 6: Thermoplastics vs. Thermosets, Polymer Additives, and Factors Affecting Plastic Properties
  7. Question 7: Applications of Numerical Control, NC vs. Conventional Machines, and the Role of Sensors

December 2015

  1. Question 1: Steel vs. Cast Iron, Property-Governing Factors, and the Effect of Alloying and Heat Treatment
  2. Question 2: Trends in Casting Industries, Plaster-Mold Casting, and Expandable-Mold Design Considerations
  3. Question 3: Turning Cutting Speed and Material Removal Rate, Metal Chip Types, and Built-Up Edge
  4. Question 4: Extrusion and Injection Molding of Plastics, Typical Products, and Reinforced-Plastic Design Characteristics
  5. Question 5: Welding-Process Selection, Oxyacetylene/Arc/Resistance Welding, and Cutting Processes
  6. Question 6: Residual Stress in Welding, Joint/Process Selection Factors, and Future Trends in Welding
  7. Question 7: Statistical Process Control, Acceptance Sampling/AQL, and the Deming and Taguchi Methods

May 2015

  1. Question 1: Non-Ferrous Alloy Characteristics, Plastics vs. Metals, and Trends in Plastics Development
  2. Question 2: Plastics vs. Metals (Restated), Polymer Additives, and Thermoplastics/Thermosets/Elastomers
  3. Question 3: Metal Chip Types, Built-Up Edge, and the Orthogonal-Cutting Shear Angle
  4. Question 4: Factors in Metal Cutting, Tool Wear/Finish/Machinability, and Current Trends
  5. Question 5: Welding-Process Selection, Oxyacetylene/Arc/Resistance Welding, and Cutting Processes
  6. Question 6: Forming/Shaping Process Characteristics, Forging Steps, and Forging Trends
  7. Question 7: NC vs. Conventional Machines, DNC/CNC Characteristics, and CNC over Conventional NC

December 2014

  1. Question 1: Manufacturing Engineer Responsibilities, Material Selection Factors, and the Annealing Process
  2. Question 2: Casting Process Selection, S​hell-Molding, and Permanent-Mold Casting
  3. Question 3: Drilling Cutting Time, and the Action and Effects of Cutting Fluids
  4. Question 4: Extrusion and Injection Molding of Plastics, Typical Products, and Reinforced-Plastic Design Characteristics
  5. Question 5: Grinding Operation Characteristics, Design Considerations, and the Economics of Surface Finish/Accuracy
  6. Question 6: Residual Stress in Welding, Joint/Process Selection Factors, and Future Trends in Welding
  7. Question 7: DNC/CNC Characteristics, Uses of Statistical Quality Control, and an X (Individuals) Control Chart

May 2014

  1. Question 1: Steel vs. Cast Iron, Property-Governing Factors, and the Effect of Alloying and Heat Treatment
  2. Question 2: Trends in Casting Industries, Plaster-Mold Casting, and Expandable-Mold Design Considerations
  3. Question 3: Turning Cutting Speed and Material Removal Rate, Metal Chip Types, and Built-Up Edge
  4. Question 4: Forming/Shaping Process Characteristics, Forging Steps, and Forging Trends
  5. Question 5: Resistance Welding, Spot vs. Seam Welding, and Oxyfuel Gas Cutting
  6. Question 6: Grinding Operations, Finishing Operations, and the Economics of Automating Grinding/Finishing
  7. Question 7: Applications of Numerical Control, NC vs. Conventional Machines, and the Role of Sensors

December 2013

  1. Question 1: Manufacturing Engineer Responsibilities, Material Selection Factors, and the Annealing Process
  2. Question 2: Casting Process Selection, S​hell-Molding, and Permanent-Mold Casting
  3. Question 3: Metal Chip Types, Built-Up Edge, and the Orthogonal-Cutting Shear Angle
  4. Question 4: Factors in Metal Cutting, Tool Wear/Finish/Machinability, and Current Trends
  5. Question 5: Welding-Process Selection, Oxyacetylene/Arc/Resistance Welding, and Cutting Processes
  6. Question 6: Thermoplastics vs. Thermosets, Polymer Additives, and Factors Affecting Plastic Properties
  7. Question 7: Statistical Process Control, Acceptance Sampling/AQL, and the Deming and Taguchi Methods

Undated paper

  1. Question 1: Multiple-Choice — Hot Forming, I-Beam Forming Processes, and Chip Formation in Metal Machining
  2. Question 2: Sand-Casting Terminology — Down-Runner Base, Expendable Core, and Pattern
  3. Question 3: Avoiding Turbulence in Casting; Forging/Stamping vs. Casting for Crankshaft Production
  4. Question 4: Powder Metallurgy — Atomization Processing Steps, Particle Size Ranges, and Major Processing Stages
  5. Question 5: Chvorinov's Rule — Solidification Time of a Sphere, Cube, and Cylinder of Equal Volume
  6. Question 6: Melting a Thermoplastic Material Uniformly and Quickly
  7. Question 7: Effect of Doubling Injection-Molded Wall Thickness on Cycle Time, Cost, and Warpage