Manufacturing Processes and Machining MCQ With Answers for JKSSB Junior Engineer (Mechanical)

Technical · 2026-10-21 · 6 min read

Manufacturing questions cover casting, welding, forming and machine tools. They test what each process is used for and basic cutting calculations. This page gives a revision list and then solved MCQs with explanations.

Quick revision list

  • Casting: patterns are made oversize for shrinkage, risers feed the shrinking metal, and cores form internal cavities
  • Welding: arc welding is a fusion process, spot welding is resistance welding, and soldering uses fillers melting below 450 °C
  • Forming: forging, extrusion, wire drawing, deep drawing and powder metallurgy
  • Machining: lathe, shaper, milling, drilling, boring, reaming, knurling and grinding
  • Tools: HSS holds hardness to about 600 °C and diamond is the hardest tool material

Worked numerical problems

  • Cutting speed: a 50 mm workpiece rotating at 400 rpm has a cutting speed of πDN ÷ 1,000 = π × 50 × 400 ÷ 1,000 = 62.8 m/min
  • Turning time: to turn a length of 120 mm at a feed of 0.2 mm/rev and 400 rpm takes L ÷ (f × N) = 120 ÷ (0.2 × 400) = 1.5 minutes
  • Material removal rate: with a cutting speed of 60 m/min (60,000 mm/min), a feed of 0.2 mm/rev and a depth of cut of 2 mm, the rate is 60,000 × 0.2 × 2 = 24,000 mm³/min
  • Punching force: punching a 20 mm hole in 2 mm sheet with a shear strength of 300 MPa needs π × 20 × 2 × 300 = 37.7 kN
  • Welding heat input: 25 V and 200 A give 5 kW. At a travel speed of 5 mm/s, the heat input is 5,000 ÷ 5 = 1,000 J/mm
  • Extrusion ratio: a billet of 100 mm diameter extruded to a bar of 25 mm diameter has a ratio of (100 ÷ 25)² = 16

Casting in more detail

A casting process has these steps: make the pattern, prepare the mould with sand, place the core if needed, pour the molten metal, let it solidify, remove the casting and clean it. Pattern allowances cover shrinkage, machining, draft, shake and distortion. The gating system leads the metal into the mould, and the riser feeds the casting as it shrinks. Defects include blowholes, cold shuts, misruns and shrinkage cavities.

Welding processes compared

  • Arc welding: an electric arc melts the metal, and a flux coating or gas protects the weld
  • MIG and TIG: an inert gas protects the weld. TIG uses a tungsten electrode that does not melt
  • Gas welding: an oxy-acetylene flame melts the joint
  • Resistance welding: heat comes from the resistance to current at the joint, as in spot welding
  • Soldering and brazing: a filler metal melts below the parent metal's melting point

Machine tools

A lathe turns the work against a fixed tool, and it can do facing, turning, taper turning, threading, drilling and knurling. A shaper uses a reciprocating single-point tool, and a planer moves the work. A milling machine uses a rotating multi-point cutter, with up-milling and down-milling modes. A drilling machine makes round holes, and a grinding machine finishes surfaces with an abrasive wheel.

Tool materials

The hardness and heat resistance of tool materials increase from carbon steel to high-speed steel, cemented carbide, ceramics and diamond. High-speed steel keeps its hardness to about 600 °C. Cutting fluids cool and lubricate the cutting zone and wash away chips.

Questions candidates ask

What is the purpose of a riser? It holds molten metal to feed the casting as it shrinks.

Which process makes seamless pipes? Extrusion and piercing of billets are used for seamless tubes.

What does tool wear depend on? Cutting speed has the largest effect, followed by feed and depth of cut.

What is the advantage of cutting fluid? It cools the tool and the work, reduces friction and washes away chips.

Revision tip

Group the processes into casting, forming, joining and machining. For each, write one example product, one advantage and one defect. This three-line summary is enough to answer most descriptive questions in the exam.

Practise

Solve the MCQs below, then read the exam guide. Next: heat transfer and power plants.

By Shivam · Written with AI assistance and fact-checked · Questions on this page are original · Editorial policy · Report an error

Practice questions

Q1. Moulding sand is made mainly of silica along with:

  1. Coal and oil
  2. Lime and iron
  3. Cement and gravel
  4. Clay and moisture
Show answer

Clay and moisture — Clay acts as the binder and moisture activates it.

Q2. A pattern used in casting is made:

  1. Twice the size
  2. Smaller than the casting
  3. Slightly larger than the casting
  4. Exactly the size of the casting
Show answer

Slightly larger than the casting — Allowances are added for shrinkage, machining and draft.

Q3. The allowance given to a pattern to allow for contraction of the metal on cooling is the:

  1. Shrinkage allowance
  2. Shake allowance
  3. Machining allowance
  4. Draft allowance
Show answer

Shrinkage allowance — Patterns are made oversize by the contraction amount, using a shrink rule.

Q4. The taper given to the vertical faces of a pattern is called:

  1. Camber
  2. Rapping
  3. Draft
  4. Chamfer
Show answer

Draft — It lets the pattern be withdrawn from the mould without damage.

Q5. The purpose of a riser in a casting is to:

  1. Feed molten metal to compensate for shrinkage
  2. Pour the metal
  3. Support the core
  4. Let air in
Show answer

Feed molten metal to compensate for shrinkage — The riser solidifies last.

Q6. A core is used in casting to:

  1. Strengthen the mould
  2. Hold the pattern
  3. Form internal cavities and holes
  4. Cool the casting
Show answer

Form internal cavities and holes — Cores are placed in the mould cavity before pouring.

Q7. Die casting is best suited for:

  1. Very large steel castings
  2. Large-scale production of small non-ferrous parts
  3. One-off components
  4. Cast iron pipes
Show answer

Large-scale production of small non-ferrous parts — Metal is forced into a steel die under pressure.

Q8. Centrifugal casting is used for making:

  1. Sheet metal parts
  2. Solid gears
  3. Large flat plates
  4. Hollow cylindrical parts such as pipes and liners
Show answer

Hollow cylindrical parts such as pipes and liners — Molten metal is thrown against the mould wall by rotation.

Q9. Which of these is a fusion welding process?

  1. Arc welding
  2. Cold pressure welding
  3. Resistance spot welding
  4. Forge welding
Show answer

Arc welding — In fusion welding the parent metal is melted.

Q10. The gas used with oxygen in gas welding is:

  1. Hydrogen chloride
  2. Methane
  3. Acetylene
  4. Nitrogen
Show answer

Acetylene — The oxy-acetylene flame reaches about 3,200 °C.

Q11. In oxy-acetylene welding, a neutral flame has:

  1. Excess oxygen
  2. Only acetylene
  3. Excess acetylene
  4. Equal volumes of oxygen and acetylene
Show answer

Equal volumes of oxygen and acetylene — It is used for welding mild steel.

Q12. In MIG welding, the shielding gas protects the weld pool from:

  1. Sparks
  2. Dust only
  3. Atmospheric oxygen and nitrogen
  4. Moisture only
Show answer

Atmospheric oxygen and nitrogen — Argon or carbon dioxide is commonly used.

Q13. Spot welding is a form of:

  1. Resistance welding
  2. Gas welding
  3. Brazing
  4. Arc welding
Show answer

Resistance welding — Heat is produced by the resistance to current flow at the joint.

Q14. Soldering differs from brazing in that soldering uses a filler metal that melts:

  1. Below 450 °C
  2. At the melting point of the parent metal
  3. Above 450 °C
  4. Only above 1,000 °C
Show answer

Below 450 °C — Brazing uses fillers melting above 450 °C.

Q15. Hot working of metals is done:

  1. Below the recrystallisation temperature
  2. At absolute zero
  3. At room temperature
  4. Above the recrystallisation temperature
Show answer

Above the recrystallisation temperature — It refines grain and needs less force.

Q16. Which of these is a forging operation?

  1. Milling
  2. Upsetting
  3. Honing
  4. Boring
Show answer

Upsetting — Upsetting increases cross-section by reducing length.

Q17. Extrusion is used to produce:

  1. Long components of uniform cross-section
  2. Complex castings
  3. Threaded holes
  4. Gears by cutting
Show answer

Long components of uniform cross-section — Metal is forced through a die opening.

Q18. Drawing of wire is a:

  1. Joining process
  2. Machining process
  3. Casting process
  4. Cold working process
Show answer

Cold working process — Wire is pulled through a die of decreasing size.

Q19. Which process is used for making cups from sheet metal?

  1. Extrusion
  2. Forging
  3. Deep drawing
  4. Rolling
Show answer

Deep drawing — A punch pushes the sheet into a die cavity.

Q20. Powder metallurgy involves which steps?

  1. Turning, drilling and grinding
  2. Blending, compacting and sintering
  3. Melting, pouring and cooling
  4. Heating, hammering and quenching
Show answer

Blending, compacting and sintering — It is used for self-lubricating bearings and carbide tools.

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