Amp Question Bank Chapter 4

1) NAME VARIOUS SURFACE COATING PROCESS
 Electroplating
 Galvanizing
 Plastic coating
 Organic coating
2) NAME VARIOUS SURFACE CLEANING PROCESS AND

EXPLAIN ANY ONE
 Chemical cleaning
 Mechanical cleaning
 Ultrasonic cleaning
 Flame cleaning
Chemical cleaning- acid cleaning
This cleaning is used for removing unwanted pigments and compounds which
are mostly oxides of metal and also used to remove oil and grease.
In this process either dilute sulphuric. Hydrochloric or phosphoric acid is
sprayed on the component or the part is dipped into tank, agitated and then
washed properly.
Acid cleaning causes hydrogen embitterment that is absorbing of hydrogen by
stell which can be reduced by heating.
3) LIST FACTORS AFFECTING ON SELECTION OF SUEFACE

FINISHING PROCESS. LIST APPLICATION OF LAPPING,
HORNING, BUFFING AND BURNISHING.
A) FACTORS AFFECTING SELECTION OF SURFACE FINISHING

PROCESS ARE
 Shape of surface
 Dimensional accuracy
 Types of marks on the surface.
 Surface condition
 Allowable metal loss
 Fine surface finish
Application
 Lapping
Moulding dies, limit gauges, surface plate, engine valves
 Horning
Engine cylinder bearing gun barrel ring gauges
 Buffing
It is used to polish sift metal including copper and brass as well as
plastics.
 Burnishing
cutting tools, turbine blades, needles, sanitary pipes
4) ENLIST FOUR FACTORS AFFECTING SLECTION OF CLEANING

PROCESS.
 Types of contaminants
 Composition of metal
 Condition of metal
 Allowable metal loss
5) DESCRIBE WITH NEAT SKETCH THE SURFACE TREATMENT

PROCESS USED TO BUILT-UP WORN-OUT METAL COMPONENTS
OF AUTOMOTIVE ENGINES.
 Metal spraying is to be used for building up worn out metal component
 Base metal is first prepared, cleaned for metal spraying.
 Metal is sprayed by heating
 Then it finished by grinding
 Metallic gun consists of gas torch with a hole in centre of the tip for
feeding metal wire there is a small turbine and tube to feed the wire into
the gun.
 air cap around the torch tip and nozzle supplies a blast of air to automize
(Convert metal inti minute drops) the molten metal.
 This metal is sprayed ono the prepared metal
 Wire is fed to spray gun at a definite rate melted by oxyacetylene flame
6)LIST MICROFINISHING PROCESS. SELECT AND EXPLAIN THE
MICROFHINISHING PROCESS TO OBTAIN CORRECT HOLE
GEOMETERY
A) micro finishing process are
 Buffing
 Superfinishing
 Honing
 Burnishing
Process used for making perfect geometry hole is honing
Honing is mostly used for finishing round hole by means if bonded
abrasive stones called hones.
It is used to correct hole geometry in component, honing is used as a
micro finishing process.
It is used to correct roundness, taper, tool, arks and axial distortion.
Horning stone is made up of common abrasive and bonding material with
sulphur resin or wax is used to improve cutting action and tool life.
 Honing tool moves in circular motion and reciprocates for creating a
smooth finish.
Application of honing process are
 Engine cylinder
 Piston pin
 Gun barrel
 Bearing
7) STATE APPLICATION OF SURFACE FINISHING PROCESS
A) NEED OF SURFACE FINISHING PROCESS ARE

Improve resistance to wear
Reduce adhesion
Improve lubrication
Improve resistance to corrosion and oxidation
Rebuild surface of worn-out component
Applying decorative features
APPLICATION OF SURFACE FINISHING PROCESS

Smoothing surface of components to reduce friction
Creating holes with perfect geometry
Making components if automobile, boats, motor cycle etc.
Preparing repairing of worn-out gears.
8)STARE ADVANTAGES OF METALLIC COATING PROCESS
A) METALLIC COATING PROCESS INCLUDES FOUR PROCESSES
Electroplating
Hot-dipping
Galvanizing
Metal spraying
Advantages
 Protecting material from physical damage.

 Protecting from atmospheric gases and oxygen
 Preventing oxidizing and corrosion
 Repairing worn out components
 Beautifying the workpiece or base metal
 Increasing life of metal component
 Filling up surface irregularity
 Changing or modifying properties of base metal
 Used where application of paint is not possible.
9) EXPLAIN BUFFING AND HORNING OPERATIONS

A) HORNING-( explain horning same as question no 6)
 BUFFING- buffing is used for give a much higher, lustrous, reflective
finish that cannot be obtained by polishing.
 The buffing process consist in applying very fine abrasive with rotating
wheel. Buffing wheels are made of disc of linen, cotton, broad cloth and
canvass.
 They are made more or less firm by the amount of stitching used to fasten
the layers of the cloth together.
 Abrasive is mixed with binder and is applied either on the buffing wheel
or on the work.
 Abrasive may contain of iron oxide, chromium oxide, emery etc.
 Binder is a paste containing various mixtures of wax, with grease,
paraffin, and kerosene, and other liquids.
 work piece is bought in contact with revolving cloth buffing wheel which
has abrasive with charged particles.
 It removes minute amount of metal from work piece eliminate fine
scratch.
 It is used to apply high luster
APPLICATION
 Automobile component
 Motorcycle
 Boats
 Tools
10)LIST ANY FOUR SURFACE FINNISHING PROCESS
A) four surface finishing process are

 Lapping
 Horning
 Burnishing
 Buffing
11)EXPLAIN LAPPING PROCESS WITH NEAT SKETCH
A) lapping is basically an abrasive process in which lose abrasive function as

cutting points finding momentary support of the lap
Lapping process involves passing a part between one or two large flat lap plates
on wheel.
Used for correcting minor imperfections of shape refine surface finish
Used for flat or slightly spherical surface.
Used to achieve super flat surface and incredible tight tolerance.
Application- types –
Optical lenses machine lapping, hand
Metallic bearing surface

12)EXPLAIN ELECTROPLATING PROCESS
A) electroplating
 Electroplating may be described as a process of covering a surface or

object usually metallic with a thin adherent coating of same or other
metal by electrolysis.
 A dc voltage is applied between parts to be plated (which is made
cathode) and anode material that is material to be plated
 That is reduction happens at cathode and oxidation occurs at anode
 Both of the metals are submerged in electrolytic solution during
electrolysis cathode turns negative and anode gets positive, positive ions
of anode move from anode and sticks on cathode.
 Chemical oxide formed due to reduction of cathode stick to anode
oxidizing it.
 Due to this cathode is kept as material that is to be coated and anode is
coating material.
 Chromium plating is widely used because of its pleasing appearance and
its resistance to corrosion and wear.

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1) NAME VARIOUS SURFACE COATING PROCESS

2) NAME VARIOUS SURFACE CLEANING PROCESS AND

3) LIST FACTORS AFFECTING ON SELECTION OF SUEFACE

A) FACTORS AFFECTING SELECTION OF SURFACE FINISHING

4) ENLIST FOUR FACTORS AFFECTING SLECTION OF CLEANING

5) DESCRIBE WITH NEAT SKETCH THE SURFACE TREATMENT

A) micro finishing process are

Application of honing process are

A) NEED OF SURFACE FINISHING PROCESS ARE

APPLICATION OF SURFACE FINISHING PROCESS

8)STARE ADVANTAGES OF METALLIC COATING PROCESS

A) METALLIC COATING PROCESS INCLUDES FOUR PROCESSES

 Protecting material from physical damage.

9) EXPLAIN BUFFING AND HORNING OPERATIONS

A) four surface finishing process are

11)EXPLAIN LAPPING PROCESS WITH NEAT SKETCH

A) lapping is basically an abrasive process in which lose abrasive function as

Used for correcting minor imperfections of shape refine surface finish

Used for flat or slightly spherical surface.

Used to achieve super flat surface and incredible tight tolerance.

Optical lenses machine lapping, hand

Metallic bearing surface

 Electroplating may be described as a process of covering a surface or

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