Manufacturing Industrial Engineer Interview Questions & Answers

  1. Question 1. What Is The Important Characteristics Of Plastics?

    Answer :

    It can be molded into finished product by application of heat and pressure.

  2. Question 2. What Are The Advantages Of Plastics Over Metals?

    Answer :

    • Low weight 
    • Corrosion resistance 
    • Insulation properties
    • Electrical properties
    • Cheaper 
    • Easy to handle 
    • Surface properties 
    • Reusable
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  4. Question 3. Explain The Disadvantages Of Plastics?

    Answer :

    • Low strength 
    • Low heat resistance
    • Poor mechanical properties
    • Difficulty to repair
  5. Question 4. How To Classify The Plastics?

    Answer :

    • Natural : milk of rubber tree, cellulose
    • Semi synthetic
    • Synthetic
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  7. Question 5. Types Of Plastics Based On Chemical Behavior?

    Answer :

    • Thermo plastics 
    • Thermosetting plastics
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  9. Question 6. Difference Between Thermo Set And Thermo Plastics?

    Answer :

    Thermoplastics:

    • Can be re softened and reused
    • No chemical changes during heating.
    • In granular form
    • Needle structure 
    • Hard but not brittle

    Thermo set plastics:

    • Cannot be re softened and reused
    • Chemical changes during heating etc.
    • In powder form
    • Cross linked structure 
    • Hard and brittle
  10. Question 7. Give Example Of Thermoplastics?

    Answer :

    ABS, PP, CA, PMMA, PS, PC, POM etc.

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  12. Question 8. Perspex Is The Trade Name Of ?

    Answer :

    CA

  13. Question 9. Nylon Is The Trade Name Of ?

    Answer :

    PA

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  15. Question 10. Delrin Is The Trade Name Of?

    Answer :

    POM

  16. Question 11. Teflon Is The Trade Name Of ?

    Answer :

    PTFE

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  18. Question 12. What Is Mfi?

    Answer :

    Flow capacity of different grades of thermoplastics are inversely proportional to molecular weight.

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  20. Question 13. About Abs?

    Answer :

    Shrinkage 0.5%. It is heat resistant, provides good insulation and exhibit electrical properties. Examples are general purpose safety helmets, pipe fittings, television, radio etc.

  21. Question 14. About Ca ?

    Answer :

    Shrinkage 0.3-0.8%. Its main properties are transparency and surface texture. Examples are Tool handle, goggles, TV screens.

  22. Question 15. About Hdpe?

    Answer :

    Shrinkage 3-4%. Main features of HDFE are high density, rigidity, strength, hardness and chemical resistance. Examples are milk bottle crates, fish boxes etc.

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  24. Question 16. About Ldpe?

    Answer :

    Shrinkage 0.8-1.5%. It is crystalline and not available in transparent form. Examples are shopping baskets, waste baskets etc.

  25. Question 17. About Pa?

    Answer :

    Shrinkage 0.7-1.5%. It is tough and high rigid. Examples are light duty gears, sprockets, bearings etc.

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  27. Question 18. About Pc?

    Answer :

    Shrinkage 0.5-0.7%. It is known optical transparency, rigidity and toughness. Examples are goggles, lenses, safety helmets etc.

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  29. Question 19. About Pp?

    Answer :

    Shrinkage 1-3%. It is flammable and degradable in sun light and stable. Examples are air cleaner, garden furniture etc.

  30. Question 20. About Ps?

    Answer :

    Shrinkage 0.2-0.8%. It is clear, brittle and it can be easily molded. Examples are toys, house hold appliances, electronic housings etc.

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  32. Question 21. About Pvc?

    Answer :

    Shrinkage (FLEXI 1.5-3%,RIGID 0.2-0.4%). It is rigid and not very tough and very low cost. Example – Pipes fittings.

  33. Question 22. Examples For Thermosetting Materials ?

    Answer :

    Alkyds, epoxies, pf, mf, urea, polyester

  34. Question 23. What Is Fillers And Additives?

    Answer :

    Adding of small molecules to plastics to get some characteristics (color, flexibility etc.). Fillers are commonly used with thermosetting plastics. Additives are of two types,

    • Physical means such as plasticizer
    • Chemical means— stabilizer.
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  36. Question 24. What Are The Mold Release Agents?

    Answer :

    • External with mold surface e.g. Polyvinyl alcohol 
    • Internal with resins eg. Silicon oil
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  38. Question 25. What Are The Types Of Injection Molding Machines?

    Answer :

    • Plunger injection cylinder 
    • Two stage plunger injection cylinder 
    • Pre plasticizer two stage screw injection cylinder 
    • Reciprocating screw injection cylinder
  39. Question 26. What Are The Divided Sections Of Screw Of Injection Molding Machines ?

    Answer :

    • Feed zone 
    • Compression zone 
    • Melting zone
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  41. Question 27. What Do You Meant By Nozzle ?

    Answer :

    Nozzle connected to the end of the barrel through which soften materials inserted in the mold.

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  43. Question 28. What Are The Types Of Nozzle ?

    Answer :

    • Reverse taper (melt valve)- for PA, ABS etc.
    • Removable tip
    • Standard of general purpose
  44. Question 29. Define Drooling ?

    Answer :

    Leakage of plastic material through the nozzle in between shots.

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  46. Question 30. What Is Injection Capacity Or Short Capacity?

    Answer :

    Maximum volume material injected by the screw during one cycle of operation.

  47. Question 31. What Is Plasticizing Capacity ?

    Answer :

    It is the amount of material that can be processed by the machine per hour. It is expressed in kg/h.

  48. Question 32. What Is Injection Pressure?

    Answer :

    It is the maximum pressure by which the material is injected through the nozzle. It is given in kg/cm2.

  49. Question 33. What Is Injection Rate Or Injection Velocity ?

    Answer :

    It is the maximum rate at which the screw can inject or shoot materials from the barrel during one shot.

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  51. Question 34. What Do You Meant By Clamping Force?

    Answer :

    It is the maximum force that the clamping system can exert on the mold or it is the maximum force by which the mold halves can be closed together. It is given in ton or kilo Newton.

  52. Question 35. What Is Maximum Daylight?

    Answer :

    It is the maximum distance that the machine platen can be separated from each other and it can be obtained by adding the maximum mold thickness to the maximum opening stroke.

  53. Question 36. What Is A Mold ?

    Answer :

    It is a custom build tool in which we converts plastic raw material into finished product.

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  55. Question 37. What Are The Main Elements Of Mold ?

    Answer :

    The main parts of molds are core and cavity.

  56. Question 38. What Are The General Types Of Mold ?

    Answer :

    Injection molds, compression molds, transfer molds.

  57. Question 39. What Are The Types Of Injection Mold ?

    Answer :

    • Two plate mold 
    • Three plate mold 
    • Hot runner mold 
    • Insulated runner mold 
    • Hot manifold mold 
    • Stacked mold
  58. Question 40. What Is Two Plate Mold ?

    Answer :

    Mold which consists of core and cavity situated in plates. It is logical type tool where component require large gate. For simple type components there is only one daylight.

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  60. Question 41. What Is 3 Plate Mold?

    Answer :

    It consists feed plates with core and cavity.

  61. Question 42. What Is Hot Runner Mold?

    Answer :

    In this, runner kept hot to keep the molten metal into fluid state also called runner less mold. In this, runner contained in a plate of its own runner section of the mold is not opened during molding cycle.

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  63. Question 43. Note Down The Advantages Of Runner Mold ?

    Answer :

    • No molded side products 
    • No separation of gait
    • Cycle time can be reduced
  64. Question 44. What Is Insulated Runner Mold ?

    Answer :

    It is a variation of hot runner mold in this type of molding. The outer surface of the material in the runner acts as a insulator.

  65. Question 45. What Is Hot Manifold Mold ?

    Answer :

    This is a variation of the heated hot runner and not the runner plate. This is done using electric cartridge.

  66. Question 46. What Do You Meant By Stacked Mold?

    Answer :

    A stacked mold is a multiple two plate mold with mold placed one over the other. A stacked mold construction doubles the output from a single molding machine and requires the same clamping force.

  67. Question 47. Explain About Injection Molding?

    Answer :

    In this process, the plastic material is injected in to the mold through a sprue bush by means of a screw plunger. This process can be used for both thermosetting and thermoplastic materials.

  68. Question 48. What Is Compression Molding?

    Answer :

    In this process, the plastic material is placed in the cavity and use a force for compressing the compound as the mold closes, these molds are generally used for thermosetting materials.

  69. Question 49. What Is Transfer Mold?

    Answer :

    In this process, the plastic materials is transferred from a transfer pot and then forced in to the cavity by means of plunger. This method is used for molding thermosetting materials only.

  70. Question 50. Write A Short Note About Blow Molding ?

    Answer :

    Blow molding is very much like compression molding because the blow mold generally closes on a hollow shape that has been deposited in between the halves of the mold. Air or gas pressure is introduced at the center. This internal pressure causes a flow of the heated material in to intimate contact with the relatively cold mold sections. Here the plastic material solidifies and is subsequently ejected.

  71. Question 51. Explain Vacuum Molding?

    Answer :

    The mold used for this process is similar that of the female half of the compression or blow mold auxiliary equipment on the machine heats the material and drags it over the cavity as indicated by the precise technique chosen.

  72. Question 52. Elaborate About Rotational Molding?

    Answer :

    The machine provides the means of holding the mold and rotating it about two axis at the same time. This rotation causes the powdered material that was loaded in to the mold before it was clamped in to the machine to solidify and cling to the wall of the mold.

  73. Question 53. What Is Impression ?

    Answer :

    Gap between core and cavity is called impression.Impression provides the shape of the component.

  74. Question 54. What Do You Meant Cavity?

    Answer :

    Female portion of the mold and it gives external form.

  75. Question 55. What Is Core ?

    Answer :

    Male portion of the mold and it gives internal form.

  76. Question 56. What Is Sprue Bush?

    Answer :

    Connecting member between register ring and runner.

  77. Question 57. What Is Register Ring ?

    Answer :

    It is used to align the mold with machine platen.

  78. Question 58. What Is Runner?

    Answer :

    Connecting member between gate and sprue bush.

  79. Question 59. What Is Gate?

    Answer :

    Connecting member between impression and runner.

  80. Question 60. How Can We Calculate The Cycle Time Of Mold?

    Answer :

    Cycle time Tc=m*3600/P

     Where ,Tc =minimum cycle time obtainable 

     M=mass of the shot 

    P=plasticizing capacity of the machine with the particular polymer being molded (kg/h)

  81. Question 61. What Is Parting Surface?

    Answer :

    The surface where top and bottom half closed together and prevents the loss of plastic material from the impression.

  82. Question 62. What Are The Types Of Parting Surface?

    Answer :

    Flat and non flat

  83. Question 63. Name The Types Of Non Flat Parting Surfaces?

    Answer :

    Straight, stepped and angular.

  84. Question 64. What Do You Meant Flash ?

    Answer :

    If the parting surfaces are not properly matched, the molding material from the impression will escape through the gap. This escaped melt is called the flash.

  85. Question 65. Why Do We Provide Vent In Mold?

    Answer :

    Vents are provided in the mold to allow such air to escape freely. The vent is a shallow slot not more than 0.05 mm deep and 3mm wide. If the depth is more, the plastic material can pass through the slot and leave a flash mark.

  86. Question 66. What Are The Types Of Runner ?

    Answer :

    • Fully rounded
    • Rectangular
    • Hexagonal
    • Trapezoidal
    • Modified trapezoidal
  87. Question 67. Explain Briefly About Sprue Gate ?

    Answer :

    When the molding is directly fed from a sprue or secondary sprue, the feed section is term as sprue gate.The main disadvantage with this type of gate is that it leaves a large gate mark on the molding. This sprue gate is used only for single impression molds.

  88. Question 68. What Is Rectangular Gate?

    Answer :

    This is the general purpose gate and it is a rectangular channel machined in on mold plate to connect the runner to the impression.

  89. Question 69. Write A Short Note About Fan Gate?

    Answer :

    Fan gate can be considered as the other type of edge gate but it does not have a constant width and depth. The fan shape spreads the flow of the melt as it enters the impression and a more uniform filling is obtained with less flow marks and surface finish.

  90. Question 70. What Is Tab Gate?

    Answer :

    This is particular gating technique for feeding solid block types moldings. This is mainly used to avoid undesirable jetting on the molded part.

  91. Question 71. What Is Overlap Gate ?

    Answer :

    It can be considered as a variation of basic rectangular edge gate and is used to feed certain type of molding. In this type of gate we have a better control over the flow rate. Main disadvantage is that it leaves big remnant mark after degiating.

  92. Question 72. What Is Diaphragm Gate ?

    Answer :

    This gate is used for single impression tubular shaped moldings on two plate molds.

  93. Question 73. What Is Ring Gate?

    Answer :

    The function of this gate is identical to that of a diaphragm gate. This type of gate is used for tabular type moldings when more than one impression is required in a simple two mold.

  94. Question 74. What Is Film Gate?

    Answer :

    This is a long rectangular type edge gate and it is used for large thin walled components to assist in the production of war page free products.

  95. Question 75. What Is Pin Gate?

    Answer :

    Used for 3 plate mold and under feed mold. Small degating mark will be there.

  96. Question 76. What Is Round Edge Gate?

    Answer :

    This gate is formed by machining a matching semi circular channel in both mold plates between the runner and impression.

  97. Question 77. What Is Submerged Gate?

    Answer :

    Automatic degating with less mark also called as sub surface gate or submarine gate.

  98. Question 78. What Is Winkle Gate?

    Answer :

    This is a curved variation of the subsurface gate and for that reason it is sometimes called a “curved subsurface gate” or “curved tunnel gate”.

  99. Question 79. What Are The Types Of Injection Techniques ?

    Answer :

    1. Pin injection 
    2. Sleeve injection
    3. Stripper bar injection
    4. Blade injection
    5. Valve injection
    6. Air injection
    7. Stripper ring injection
    8. Stripper plate injection
  100. Question 80. What Is Pin Injection ?

    Answer :

    This is the most common and simple type of injection. The molding is ejected by the application of a force by ejector pins.

  101. Question 81. What Do You Meant By Sleeve Injection ?

    Answer :

    In this method, the molding is ejected by means of a hallow ejector pin which is called sleeve.

  102. Question 82. What Is Stripper Bar Injection?

    Answer :

    This method of injection is suitable for thin wall box type moldings because of the effective injection area obtainable are greater.

  103. Question 83. What Is Blade Injection ?

    Answer :

    The main purpose of blade ejector is for the injection of very slender parts such as ribs and other projections which cannot be satisfactorily ejected by the standard type of ejector pin.

  104. Question 84. What Is Valve Injection ?

    Answer :

    A valve ejector is basically a large diameter ejector pin. It is used for the injection of large components.

  105. Question 85. What Is Air Injection ?

    Answer :

    This is the simplest to install. It is easy to connect to the fixed or moving half. The medium of actuation is compressed air.

  106. Question 86. Explain Briefly Stripper Ring Injection?

    Answer :

    The stripper ring is a local stripper plate and it is used on molds with one or two impression only. The stripper ring is made to seat in the mold plate.

  107. Question 87. What Is Stripper Plate Injection?

    Answer :

    This injection technique is used mainly for the injection of circular box type moldings and for moldings with thin wall sections.

  108. Question 88. Name The Methods Used For Actuation Of Stripper Plate?

    Answer :

    1. Tie rod actuation
    2. Length bolt actuation
    3. Chain actuation
    4. Direct actuation
  109. Question 89. Define Shrinkage ?

    Answer :

    When a hot plastic cools inside a mold, it contracts by an amount depending on the material being processed and the final product is smaller than the mold size is called shrinkage.

  110. Question 90. What Are The Factors Which Affect The Increase In Shrinkage ?

    Answer :

    • Increase of material temperature.
    • Increase of mold temperature.
    • Increase in wall thickness.
    • Low injection pressure.
  111. Question 91. What Are The Factors Which Effect The Decrease In Shrinkage ?

    Answer :

    • Low melt and mold temperature
    • High injection pressure 
    • Long injection time
    • Presence of filler materials and its content
  112. Question 92. What Is Undercut Molding?

    Answer :

    A molding which has a recess or projection is termed as an undercut molding

  113. Question 93. What Do You Mean External Undercut?

    Answer :

    Any recess or projection on the outside surface of the component which prevents its removal from cavity is termed an external undercut

  114. Question 94. Name The Methods Of Split Actuation?

    Answer :

    • Finger cam actuation
    • Dog leg cam actuation 
    • Cam track actuation
    • Spring actuation
    • Hydraulic actuation
  115. Question 95. How Can We Calculate Finger Cam Length?

    Answer :

    Finger cam length =(M/Sin Q) +(2c) l Sin 2Q

    Where 

     M= split movement

     Q=angle of finger cam 

     L=working length 

     C =clearance

  116. Question 96. Where We Use Side Core And Side Cavity ?

    Answer :

    A side core is a local core which is normally mounted at right angled to the mold axis for forming a hole or recess in the side face of a molding. The side cavity performs a similar function to the side core, in that it permits the molding of components which are not in line of draw. This element allows the components with a projection or projections on one or more of their side faces.

  117. Question 97. Where We Use Form Pin Straight Action Method ?

    Answer :

    For the components which has internal undercut on one side of the wall.

  118. Question 98. What Is Single Daylight Mold ?

    Answer :

    When a basic mold is opened, there is only one space or “daylight “ between the two mold halves. This is called a single daylight mold.

  119. Question 99. Explain About Double Daylight Stripper Plate Mold ?

    Answer :

    A stripper plate mold consists of a fixed plate, a moving mold plate and a stripper plate. There are two day light when opened. This is called double daylight stripper plate mold.

  120. Question 100. What Is Underfeeding Mold?

    Answer :

    An underfeeding mold is the one in which the feed system is arranged to feed into the underside of the component.

  121. Question 101. What Are The Types Of Injection Molding Defects ?

    Answer :

    Sink mark, Streaks, Blisters/Bubbles, Weld line, Ejector marks, Cold weld, Jetting, War page

  122. Question 102. Define Sink Mark ?

    Answer :

    Sink marks are the localized contractions or the depressions on the surface of the moldings.

  123. Question 103. What Is Blister Or Bubbles ?

    Answer :

    Hollows created on or in the molded part.

  124. Question 104. What Is Weld Line ?

    Answer :

    It is the witness marks of two or more melt flow fronts at their joining zone.

  125. Question 105. What Is Jetting ?

    Answer :

    It is the prominent in-homogeneous snake like strands on the surface of molding.

  126. Question 106. What Is War Page ?

    Answer :

    War page is the deviation of the mold part from its required shape.

  127. Question 107. What Is Bulk Factor?

    Answer :

    Bulk factor is defined as the ratio of the volume of the loose powder to the volume of the molded part.

  128. Question 108. What Are The Types Of Compression Molds?

    Answer :

    • Flash mold
    • Fully positive mold
    • Semi positive mold
    • Landed positive mold
  129. Question 109. Write A Short Note About Performs ?

    Answer :

    Performs are small pellets or tablets of molding material that are formed to shape in a special performs mold at room temperature. Curing won’t takes place only densification.

  130. Question 110. Name The Types Of Transfer Molds ?

    Answer :

    • Pot transfer mold
    • Plunger transfer mold
  131. Question 111. What Is Die Casting?

    Answer :

    Pressure die casting is the process in which the molten metal is forced under high pressure into a cavity in a metal disc with in fraction of a second and allowed to solidify.

  132. Question 112. What Are The Types Of Die Casting ?

    Answer :

    • Hot chamber process
    • Cold chamber process
  133. Question 113. What Are The Types Of Die Casting Defects ?

    Answer :

    • Cold defects 
    • Hot defects
    • Miscellaneous defects
  134. Question 114. Example For Cold Defects ?

    Answer :

    Lack of fill, cold shut, severe chill, chill, flow lines

  135. Question 115. Examples For Hot Defects ?

    Answer :

    Soldering, cracks, broken part, bent part, heat marks or shrinkage pits.